Articles

Filter Content

Managing welding information more efficiently

December 16, 2014

By: ,

A company can improve only those areas of production that can be tracked and measured. In welding, information management systems can help to provide the support to bolster production efficiencies.

Continue Reading

Improving flying cutoff operations, mill productivity

December 16, 2014

By:

Tube and pipe production is a capital-intensive process, but paying close attention to the efficiency of some of the lowest-cost items, specifically the consumables, can yield big benefits in productivity. At the cutoff, proper blade choice and optimizing the cutting depth are important first steps, but it’s also necessary to diagnose saw problems and—most important of all—develop a blade replacement strategy that minimizes mill downtime.

Continue Reading

Aluminum Workshop: Why 6061 filler metal doesn’t exist

December 15, 2014

By:

Q: The most common grade of aluminum I see is 6061-T6, but I’ve never seen 6061 filler metal. Why is this? Why does everyone seem to weld 6061-T6 with 4043 or 5356 filler metal? A: You never see 6061 filler metal because, if it existed, it would be an awful filler metal. Virtually every weld you...

Continue Reading

Aluminum Workshop: Cleaning aluminum parts

December 15, 2014

By:

Q: What’s the proper method to clean aluminum parts before welding? A: Cleaning aluminum parts before welding is a two-step process. First, remove oils, grease, and other contaminants to prevent weld porosity. Second, eliminate oxide from the areas to be welded to prevent lack of fusion and...

Continue Reading

Aluminum Workshop: New wire brand may mean new parameters

December 12, 2014

By:

Q: When I run out of aluminum gas metal arc welding (GMAW) wire and buy a different brand, it doesn’t seem to weld as smoothly. Is there that much of a quality difference among brands? A: While there may be a difference in quality, you may be experiencing something else entirely. If you’ve...

Continue Reading

Pass it on

December 12, 2014

By:

Ron Covell’s 50-year career manually building autobodies for street rods, dragsters, and motorcycles is impressive, to say the least. But he doesn’t plan on hoarding all of the expertise he’s garnered over the years. His latest passion, of the last 20 years anyway, has been sharing information in his traveling workshops to current or up-and-coming autobody enthusiasts. It’s what he hopes is his longest and most impactful legacy.

Continue Reading

One metal fabricator, two value streams

December 12, 2014

By:

For decades Nu-Way Industries operated with a conventional management structure. In recent years, managers at the Des Plaines, Ill., fabricator discovered that the two kinds of orders the company processed, engineered to order and make to stock, really called for two distinct value streams, each operating under a different business model.

Continue Reading

Aluminum Workshop: Preheating aluminum

December 12, 2014

By:

Q: What preheat temperature should I use when welding aluminum? I’ve heard different numbers, and I know they can’t all be right. A: Let me begin with a bold statement: If you have the right equipment, you never need to preheat when welding aluminum. I have gas tungsten arc-welded (GTAW)...

Continue Reading

Aluminum Workshop: Alloys for furniture fabrication

December 11, 2014

By:

Q: Which alloy would you recommend for cold bending aluminum tubing or fabricating aluminum law furniture? A: First consider alloy availability. Many alloys are available as round tubing, but not all are obtainable. Most small-diameter tubing is extruded because it’s relatively economical to...

Continue Reading

Boatbuilder switches from aluminum to steel

December 11, 2014

By:

Burger Boat Co. has weathered many a storm in its 150-year history, often changing direction to incorporate new technologies and adapt to changing market conditions. When the pleasure craft industry sank in 2009, it went after commercial work, and in the process had to develop a program for working in steel, which it hadn’t done in five decades or so. With the new process came new consumables from ESAB.

Continue Reading

Aluminum Workshop: Electrical current in TIG and MIG

December 11, 2014

By:

Q: When I gas tungsten arc weld (GTAW) aluminum, I always use alternating current (AC), but when I gas metal arc weld (GMAW) aluminum, I always use direct current electrode positive (DCEP). Why the difference? Does anyone GTAW aluminum using DC? Does anyone GMAW using AC? A: In both GTAW and GMAW,...

Continue Reading

Aluminum Workshop: Determining aluminum metallurgy

December 10, 2014

By:

Q: Most of my aluminum welding involves the repair of components my customers bring me. How do I know which alloy they are made of and which filler metal to use? A: This is a good question and one to which there is no easy answer. There is no quick, cheap test that will tell you which aluminum...

Continue Reading

Engineer, weld, fabricate, test, and perfect

December 10, 2014

By:

Rando Productions juggles various projects from various customers—TV shows, commercials, theme park attractions—and each has its own timeline. It’s all one-off, nonrepeat work. Sound familiar?

Continue Reading

Aluminum Workshop: Acceptable tensile sample failure

December 9, 2014

By:

Q: We are fabricating components from ½-in.-thick 5083-H131 armor plate using robotic GMAW and 5183 filler metal. The tensile samples are failing at 41 KSI during welding procedure qualification. My customer says this is unacceptable and that the tensile samples should fail at 46 KSI or higher....

Continue Reading

2015 metal fabrication forecast: Steady as she grows

December 8, 2014

By:

Fabricators expect steady growth for 2015. At the same time, they’re gearing up to handle increasing customer demand by investing in capacity-building equipment.

Continue Reading