Consumables Articles

The devil is in the details, especially when it comes to welding processes. This technology area has information on consumables, including cutting tips, electrodes and wire, spatter prevention compounds, temporary purge dams, and welding torch components.

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Consumables Corner: Cost or classification

November 30, 2016 | By Nino Mascalco, Rob Koltz, Steve Sigler

What is more important, price or classification? The Consumables Corner guys have the answer.

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How to choose the right wire and flux for SAW

November 16, 2016 | By Robert Fox

Discovering as much as possible about the application’s requirements helps identify potentially costly and time-consuming conflicts between expectations and reality during the selection process, as opposed to during implementation. Most important, answering the following key questions provides insight into the big question: Which wire and flux is best for you?

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Consumables Corner: Preventing porosity on weldable primer-coated joints

September 23, 2016 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: A majority of our welding is done on 1/4 to 5/8-in.-thick carbon steel that has a weldable primer. Most of the welding is done on basic partial joint penetration (PJP) T-joints without any joint prep. We use an E70T-1 0.052-in.-dia. flux-core wire with a 75 percent Ar/25 percent CO2 shielding...

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So, you want to become an AWS CWI—Part II

August 24, 2016 | By Professor R. Carlisle "Carl" Smith

The letters and numbers used to classify electrodes all mean something. Understanding their meaning is important when choosing an electrode for your job. You also must be knowledgeable about these classifications to become an AWS CWI.

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Consumables Corner: Choosing the correct filler metal for mismatched base materials

July 22, 2016 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We're a small shop that builds and welds a lot of custom metal products. In many instances, the products are made from two or three different material combinations, including stainless steel at times. Is there a good rule of thumb for deciding the correct filler metal to use? A: That is a...

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Customizing your GMAW gun for the job

June 15, 2016 | By Andy Monk

Being as comfortable as possible on the job is important for mind, body, and productivity. Customizing your GMAW gun for the application can improve your personal comfort and weld quality.

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Consumables Corner: Breaking down CTOD and CVN testing

May 13, 2016 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We're a job shop and much of our work is customized or unique. Because of this, we have to work with multiple welding codes and sometimes we have to verify welding procedures. We have been bidding on some new projects that have welding crack tip opening displacement (CTOD) requirements. How is...

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When your GMAW gun's ablazin'

May 11, 2016 | By Jerome Parker

Overheating is a symptom of what could turn into catastrophic gun failure. Striking the right balance between gun size and capacity can increase the efficiency of a welding operation and decrease problems, like overheating, that could damage the equipment.

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Consumables Corner: Understanding welding heat input and its effects on base materials

March 28, 2016 | By Nino Mascalco, Rob Koltz, Steve Sigler

What guidelines should a job shop follow in regards to heat input if there is no welding procedure to fall back on? The Consumables Corner team has the answer.

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What’s inside your GTAW torch?

March 16, 2016 | By Jim Watson

Welders are judged by the appearance of their beads, the strength of their welds, and their ability to pass visual and technical inspection. So why shouldn’t you scrutinize your GTAW torch components in the same way that you or someone else would scrutinize your welds? If your GTAW torch doesn’t pass inspection, there’s a good chance that your welds won’t either.

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Consumables Corner: Discovering the cause of lack of fusion in PJP joints

November 16, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We manufacture various products for the agriculture and transportation industries. A majority of our products are made from 6061 and 5652 aluminum and are joined with gas metal arc welding (GMAW-S) using a 5356 filler metal and 100 percent argon shielding gas. Most of the joints are partial...

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Consumables Corner: Welding medium-carbon to high-strength steel

September 28, 2015 | By Nino Mascalco, Rob Koltz, Steve Sigler

Q: We need to weld a 1-in.-thick AISI 1050 carbon steel plate to a 2-in.-dia. A514 steel shaft. The AISI 1050 has a yield and tensile strength of 95 KSI and 115 KSI, respectively. We know we should preheat, but we're unsure of what temperatures to use or what filler metal to select. Could you...

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Shielding gas blends for carbon steel GMAW

September 28, 2015 | By Samantha Noland

Argon and CO2 are the most commonly used gases in gas metal arc welding (GMAW). Alone, each has pronounced advantages. Together they combine to neutralize each other’s weaknesses and capitalize on each other’s strengths, all while providing you with your desired weld requirements.

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Selecting the right contact tip size

September 24, 2015 | By Tiejun Ma, Tre’ Heflin-King

Using the right-sized contact tip is critical to achieving optimal results in robotic and semiautomatic GMAW operations. Among the factors that determine the right tip size are the process and wire.

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