Arc Welding Articles

The arc welding technology area focuses on the most commonly used arc welding processes, mainly GMAW/MIG, GTAW/TIG, SMAW/stick, and plasma. The articles and press releases cover processes and power sources, plus all of the related items—electrodes and wire, wire feeders, fixtures, manipulators, positioners, and power sources. If you need information on personal protective gear, ventilation systems, and safety practices for welders, see our Safety coverage area.

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Consumables Corner: Combating dull weld appearance with metal-cored stainless steel wire

July 7, 2014

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Q: We fabricate 401 stainless steel components and have considered using metal-cored stainless steel consumables. One of the issues with metal-cored consumables is the dull appearance of the weld compared to the appearance achieved with a solid wire. What can we do to maintain a clean or shiny...

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Consumables for high-amperage welding

July 7, 2014

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High-amperage welding, whether in semiautomatic or robotic applications, pust a great amount of stress on welding consumables. By following a few tips, however, a welder can extend the life of these components.

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Consumables Corner: Nixing porosity during weld start

July 3, 2014

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Q: I work for a job shop that fabricates and welds process piping for various applications. The pipes, made from A106-88a carbon steel and 304 and 316 stainless steel, are welded using GMAW, FCAW, and GTAW. We have been experiencing porosity, primarily on the weld starts. Our shielding gas is a...

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Consumables Corner: Welding heat treatable steels

July 2, 2014

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Q: Our shop won a contract that requires welding 4130 steel. I’ve been told this is a heat-treatable steel. Can you tell me which different welding procedures have to be used to weld this material? A: The most commonly welded heat-treatable steels are 4130, 4340, and 8630. However, any steel...

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Consumables Corner: Welding weathering-grade material with a nickel-containing filler

June 27, 2014

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Q: I work for a structural steel fabricator and we are getting ready to start work on a bridge job that specifies A588 material. We have worked on this material in the past using a weathering-grade filler metal. Our engineer has recommended we use a 1 percent nickel electrode. Is this right? A:...

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Consumables Corner: Issues with incomplete fusion

June 27, 2014

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Q: Recently our shop started using metal-cored wire. On one side we perform full-penetration welds to D1.1 structural code on 3/4- to 1-1/2-in.-thick plate. On the second side we carbon-arc-gouge to clean the metal and then we do a magnetic particle inspection before welding. We encounter two...

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Consumables Corner: Figuring out FCAW Charpy V-notch failure

June 26, 2014

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Q: We performed an AWS D1.1 procedure qualification test using gas-shielded FCAW. We used a 0.052-in. E71T-9C electrode with 100 percent CO2 shielding at 200 amps and 26 V on 1-in. thick plate. We used a preheat and interpass temperature of 70 degrees F. Our pass layer sequence was three full...

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Consumables Corner: Simple steps to avoid cracking

June 25, 2014

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Q: When welding a thick section of a forged 4130 ring to a thinner A36 plate in a T-joint configuration, we experience longitudinal cracking issues that originate from the ends of the welds. The required fillet size is ½ inch. It is skip-welded 12 in. on 18-in. center-to-center spacing. The...

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Consumables Corner: Before choosing filler, know your 4140

June 24, 2014

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Q: We need to weld 4140 steel to AR 360 plate and are thinking of using an E120 electrode to try and match the strength. Is this the right electrode for our welding application? A: Before you choose a filler metal, there are a few things you should consider for this application. First, 4140...

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Consumables Corner: Pinning down the cause of porosity in SAW

June 23, 2014

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Q: Our company produces large structures fabricated from mild steel plate with a small amount of HSLA forgings ranging from 0.5 in. to 4 in. thick. Our main process is submerged arc welding (SAW) using a mild steel electrode and a neutral-bonded flux. We have been experiencing some issues with...

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Consumables Corner: Reducing weld cleanup in pulsed GMAW

June 20, 2014

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Q: Our company manufactures the main structures used to build fitness equipment. These structures are mild steel tubing of various shapes and sizes and in relatively thin material, typically 10 to 16 gauge. We are using 90 percent argon/10 percent CO2 shielding gas with a 0.035-in.-dia. ER70S-3...

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FAB 40: Merrill Fabricators’ welding school fuels local talent base

June 19, 2014

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Merrill Fabricators takes an innovative approach to the skilled labor crisis, by launching and growing its own welding school not only to fill its own ranks, but also to help grow the broader manufacturing community.

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Consumables Corner: Eliminating porosity in submerged-arc welding

June 19, 2014

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Q: Our shop manufactures bridge and structural steel components. Most of the material is A36 or A572 and welded with E70X-X class electrodes using FCAW with 75 percent Ar/25 percent CO2 shielding gas (bottle-supplied) and SAW. We're having issues with porosity in our SAW process. We find that once...

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Consumables Corner: Longitudinal cracking: A check list for prevention

June 18, 2014

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Q: We are welding several fabricated parts made from A514 (T1) steel using an AWS A5.29, 3/32-in-dia. E110 FCAW electrode. On one particular part we are experiencing longitudinal weld cracking. The structure is a 4-in. plate with a square cut out of the center and a 1.5-in. plate welded back in its...

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Consumables Corner: Addressing cracking on free-machining steels

June 17, 2014

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Q: We are a small company that fabricates and welds various parts and products for numerous companies. One of our customers is supplying us with parts for a particular weldment. All of the individual parts are made from A36 steel except for one, which is made from 12L14 steel. We are using GMAW...

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