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.
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...
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.
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...
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.
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...
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.
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.
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.
The Consumables crew assists a reader tasked with repairing a tower crane.
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...
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...
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.
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.
The Consumables Corner team counsels a company struggling with weld fusion when joining ferritic to carbon steel.
July 15, 2015 | By Jonathan Will
Flux-cored wires have unique welding characteristics and requirements, advantages, and limitations. Knowing these can help in determining whether they are the right choice for your application.