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Arc Welding 101: Plugging holes and pinholes

May 12, 2015

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Q: I am machining a bearing housing made out of 1045 and I have to plug and weld some cross holes. I am also using gas tungsten arc welding (GTAW) to eliminate a weld that is too large. My problem is that I am getting pinholes in my weld. Is it because I am welding 1018 to 1045? We didn’t machine...

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Replica cars? There’s a kit for that

May 12, 2015

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A component (kit) car manufacturer in Wareham, Mass., made two big process changes that helped streamline its manufacturing operations.

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Shop technology and 3-D CAD: Design for manufacturing

May 12, 2015

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Columnist Gerald Davis provides an overview of using CAD to develop a better design, which leads it to being more manufacturable.

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Consumables Corner: Eliminating weld cracking in restrained joints on high-strength steel

May 12, 2015

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Q: We're a construction equipment manufacturer that is finding that our customers increasingly require more components designed and manufactured from high-strength steels such as A514 or 4130. This means we have to preheat and follow slow cooling conditions, but even then certain joints or...

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Aluminum Workshop: What to know when changing shielding gas with pulsed GMAW

May 12, 2015

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Q: Recently I bought a new high-end pulsing power supply, which has different modes for all of the common materials and wire diameters. I was getting great results with 3/64-in. 5356 wire and 100 percent argon shielding gas. When I changed to a mixture of 70 percent argon/30 percent helium, the arc...

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Going beyond OSHA regulations for manganese exposure

May 11, 2015

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Complying with OSHA guidelines for manganese exposure during welding may not be doing welders any favors. One Oregon metal fabricator invited OSHA into its shop and to look for ways to reduce the potential of manganese exposure. The combination of low-manganese welding wire and proper ventilation positioning appears to have cleared the air on this subject.

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Bending and brewing

May 11, 2015

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Sheet metal worker Paul Ziegman puts in long days building stainless steel kitchen equipment for restaurants and other food-service businesses in and around Spokane, Wash. He recently opened his own such business using the same equipment and skill set.

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Trust, respect, and the skilled trades

May 11, 2015

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In 7 Success Skills for Apprentices and Skilled Trades Persons, James Sidney Harvey describes aspects of the skilled trades that you usually don’t learn in a classroom

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The unique characteristics of dual-phase steels

May 7, 2015

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The microstructure of advanced high-strength steels (AHSS) can be tailored to produce specific properties that are engineered for each application. This is why usage of AHSS grades is growing in the automotive industry, and dual-phase (DP) steels are leading the way.

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Synchronized welding

May 7, 2015

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No one doubts that welding equipment has advanced to the point where it has greatly improved welding results and productivity when compared to the technology of previous decades. That doesn’t mean that there isn’t room for improvement. Fronius has attempted to address some of GMAW’s shortcomings with its LSC welding platform.

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Making lean manufacturing work in a job shop

May 7, 2015

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Lean principles apply to all manufacturing, not just OEM settings where a few types of products are made each and every day. These tips can help a job shop fabricator to eliminate waste in its assembly area.

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Flow, quality, and operational excellence in manufacturing

May 7, 2015

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A fabricator can’t achieve operational excellence without good flow, and good flow isn’t possible without good quality. Kevin Duggan, founder of the Institute for Operational Excellence, describes how quality assurance intertwines with every process in a business.

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Effectively controlling hazardous welding fumes and gases

May 6, 2015

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Effectively reducing hazardous welding fume and gas exposure requires much more than opening windows and running fans, which in most cases does little to alleviate the problem. Here are some options to make the welding workplace much safer.

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Troubleshooting CNC plasma cutting, Part II

May 6, 2015

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The four most common cut quality issues for fabricators are dross, edge angularity, material warpage, and metallurgy of the plasma-cut edge. Your ability to achieve the best results depends on the system, torch, and consumables you are using, as well as the accurate control of such highly critical parameters as pierce height, cut height, amperage, gas type and flow rate, and cut speed.

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Right resources + enough time = safe finishing

May 6, 2015

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A shop’s finishing team has the time and resources it needs to work safely. Time comes from proper scheduling and incentives that promote safe work practices. The resources come from five key areas: working environment, personal protection, fixturing and ergonomics, tools and abrasives, and power sources.

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