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: Changing over to metal-cored wire in SAW

August 27, 2014

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Q: One of my vendors recently approached me about replacing the solid wire in my submerged arc welding (SAW) application with a metal-cored wire. Should I consider making the change? A: Depending on your application, you should certainly consider making the change. Metal-cored wires can provide...

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Consumables Corner: Lowering weld hardness in SAW

August 26, 2014

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Q: We manufacturer dual submerged arc welded (DSAW) pipe for API use. Some jobs require that the weld hardness be below 250 Vickers. We are having trouble meeting that requirement. What can we do? A: Weld hardness restrictions generally are found in pipelines designated for sour service and are...

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Consumables Corner: Selecting filler metal for robotic welding

August 22, 2014

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Q: We are just getting started in robotic welding. What advice can you give us on how to select the correct filler metal? A: As in any high-productivity application, the main consideration in selecting a filler metal for robotic welding is performance consistency. You want a wire that will...

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Consumables Corner: Storing stick electrodes

August 21, 2014

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Q: I recently saw a comment that regular stick electrodes could be overdried in ovens to the point of causing poor weld performance. Is this true? We store all our electrodes, including low-hydrogen, at 135 to 140 degrees F at all times and have not noticed any problems. We are located in Arizona,...

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Consumables Corner: Examining weld cracking, Part II—Stress, hydrogen cracking

July 16, 2014

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Editor’s Note: This is the second column in a two-part series. Q: I work in a midsized job shop, and we weld with the FCAW, GMAW, and SMAW processes. Occasionally we encounter weld cracking issues. What causes weld cracking, and what can I do to prevent it? A: Stress cracking is similar to hot...

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Consumables Corner: Horizontal fillet test troubles

July 1, 2014

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Q: For a recently acquired large structural job, we have had to qualify a single-pass 5/16-in. fillet using 0.045-in. E71T-9M flux-cored wire. We are having trouble passing the horizontal fillet test. When performing the weld break test on the horizontal fillet weld, there is incomplete penetration...

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Consumables Corner: Defining current density

June 5, 2014

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Q: Our company manufactures cylindrical structures, including tanks and smokestacks made from A36 or A572 material. The material is burned to size on a plasma table and mechanically beveled. Process limitations cause gaps in the joints during fit-up. We use a 0.045-in.-dia. solid wire with a 75...

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To infinity and beyond—with the help of a filler metal

May 19, 2014

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4943 alloy is the first aluminum filler metal developed in the U.S., designed for use in wrought commercial applications, and registered with the Aluminum Association in over 50 years. It was designed primarily to provide a consistently high-strength alternative to filler metal 4043 while maintaining various advantages of 4043. The most interesting and comprehensive series of third-party tests were conducted by NASA at the Goddard Space Flight Center for the James Webb Space Telescope project.

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How consumable quality affects welding productivity and costs

April 7, 2014

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Contrary to popular belief, ignorance isn’t bliss, particularly when it applies to making smart buying decisions. Knowing what to look for in consumables can help you make a wise choice.]

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Choosing the correct gas delivery system for metalworking - TheFabricator.com

Choosing the correct gas delivery system for metalworking

September 9, 2013

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Supplying gas to your metalworking applications can be complicated, especially if the gas needs to reach multiple locations. If you are looking for cost savings and productivity gains, consider installing gas cylinders at one main location and controlling them with a basic manifold or switchover manifold. With this method you won’t need to worry about cylinders running out of gas.

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Choosing the correct gas delivery system

September 9, 2013

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: Supplying gas to your metalworking applications can be complicated, especially if the gas needs to reach multiple locations. If you are looking for cost savings and productivity gains, consider installing gas cylinders at one main location and controlling them with a basic manifold or switchover manifold. With this method you won’t need to worry about cylinders running out of gas

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Demystifying contact tips - TheFabricator.com

Demystifying contact tips

September 5, 2013

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Contact tips are highly misunderstood components in a welding gun setup. Choosing the correct contact tip for your welding application and understanding how to keep it performing at its best are just as critical as anything else needed to produce a quality weld.

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Need a filler metal for a 300 series stainless steel? - TheFabricator.com

Need a filler metal for a 300 series stainless steel?

June 28, 2013

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Matching a consumable to a 300-series (austenitic) stainless steel is fairly straightforward, but fabricators should be aware that the various options (rod for GTAW, solid or metal-cored wire for GMAW, stick electrode for SMAW, or flux-cored wire for FCAW) have huge productivity differences.

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GMAW Aluminum

Aluminum filler metals: What you should know about selection, storage, operation, and equipment

April 5, 2013

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Aluminum requires special attention during welding. Among the critical considerations for optimal aluminum welding is proper filler metal selection.

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The impact of impact toughness - TheFabricator.com

The impact of impact toughness

March 15, 2013

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Choosing a filler metal with the right mechanical and chemical properties for your application is critical. Correct properties not only ensure the proper weld strength, but may also help prevent costly complications. In applications that endure rapid or cyclic loading, experience extreme service temperatures, or are subject to other stressors that threaten the integrity of the weld, using a filler metal that provides the proper impact toughness is especially important.

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