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12 great gadgets and die components

November 26, 2014

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Sometimes it’s the small items that make your workday easier. Standard die components with incremental improvements, such as roller cages with cylindrical rollers, and special gadgets, such as auto-indexing dimplers, can help smooth the stamping process and extend uptime.

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Aluminum Workshop: Weldability of aluminum mold plate

November 26, 2014

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Q: I’m trying to weld some very thick aluminum mold plate. I don’t know what the alloy is. The plate thickness is about 12 in. I’m having lots of cracking problems. Can you tell me what the problem might be? A: In the way of background, most of the molds used for injection or blow molding...

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Aluminum Workshop: Common porosity problems (and how to fix them)

November 26, 2014

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Q: I’m having a lot of problems with porosity in my aluminum welds. Can you tell me what’s causing it? A: As we’ve said before, all porosity in aluminum welds is caused by hydrogen, which is very soluble in molten aluminum but insoluble in solid aluminum. Generally, hydrogen comes from two...

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Vessels for coal mines

Upsizing in a downsizing economy

November 25, 2014

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Different shops have different ways of coping with and surviving business downturns. Some downsize, while others take advantage of opportunities and invest in people and equipment. Upsizing paid off for Wilson Works, Morgantown, W.V.

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Make it better, keep it better with press monitoring

November 25, 2014

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Press monitoring systems improve overall equipment effectiveness (OEE) and help identify downtime culprits. Press controls track when the machine is running and when it is not. It counts machine cycles, and can detect both empty strokes and cycles when die protection or tonnage faults exist.

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Aluminum Workshop: Explaining the causes of black smoke

November 25, 2014

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Q: I get a lot of black smoke on the surface of my aluminum welds. What is it, and how can I get rid of it? A: I can tell you what the black smoke isn’t. It is not soot and it doesn’t contain carbon, as most people think. It is, in fact, a mixture of very fine particles of aluminum oxide and...

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Aluminum Workshop: Addressing arc blow

November 25, 2014

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Q: I’m welding aluminum plate and extrusions of various alloys using both GTAW and GMAW. Sometimes I encounter what seems to be arc blow while welding, mostly with GMAW. But since aluminum isn’t magnetic, arc blow shouldn’t be possible. Is it something else? If so, what? A: This is a common...

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Straightening AHSS

November 24, 2014

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Advancements in straighteners help stampers handle advanced high-strength steels on coil feed lines.

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Aluminum Workshop: Dissecting a die casting dilemma

November 24, 2014

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Q: I weld a lot of aluminum castings. Most of the time they weld fine, but sometimes the weld blows out at me. What’s going on? A: The problem is caused by the casting process. There are three types of casting processes—sand casting, permanent mold casting, and die casting. The molds for sand...

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Aluminum Workshop: Meet tensile strength requirements with the right filler metal

November 24, 2014

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Q: I am trying to conduct a procedure qualification test on 5083-0 temper material using 5356 filler metal and gas metal arc welding (GMAW). I have welded a number of test plates, but the tensile samples always fail at a tensile strength of 37 to 39 KSI. The code requires a minimum tensile strength...

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Consumables Corner: Understanding heat input and its limitations

November 21, 2014

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Q: We manufacture structures for the utility industry and primarily weld A36, A572-Gr. 50 and A871-Gr. 65. Recently we converted some of our welding processes to higher-deposition submerged-arc welding (SAW) but are concerned about the amount of heat we are adding from welding. What is the...

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Arc Welding 101: Those dang CVN requirements

November 21, 2014

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Q: Table 4.6 of AWS D1.1: 2010 is a list of supplementary essential variable changes that would require weld procedure specification (WPS) requalification due to Charpy V-notch (CVN) testing requirements. Under base metal (item 2) it indicates: Minimum thickness qualified is T or 5/8 inch...

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Aluminum Workshop: Determining contact tip size

November 21, 2014

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Q: What is the right contact tip size for using 0.0468-in. filler wire to gas metal arc weld aluminum alloys? Some people use a tip that is one size larger (for example, a 0.0625-in. tip on 0.0468-in. wire), while others use the size the manufacturer specifies for 0.0468-in. wire. Still others use...

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Aluminum Workshop: Welding fumes in aluminum MIG

November 21, 2014

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Q: I just started gas metal arc welding (GMAW) aluminum in my shop. I have noticed that a lot of white smoke comes off when I weld. Is this dangerous? Are there other issues with fumes I need to be aware of when welding aluminum? How concerned should I be? A: You are absolutely doing the right...

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The case for consumables

November 21, 2014

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New-generation GMAW consumables reduce the number of components, eliminate threads in the electrical path, and feature gas ported contact tips that run cooler and can accommodate more wire in a single tip.

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