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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Resolving the challenges of welding coated steels

September 13, 2005

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The increased use of coated steels has resulted in an intensified search for solutions to the problems posed by joining these materials. High levels of spatter and welding fume, weld porosity, and poor bead shape are common. These problems lead to increased post-weld cleaning costs, reduced quality, greater rework, and an overall reduction in productivity. The right wire size and type, matched with the most appropriate shielding gas, can substantially improve gas metal arc welding (GMAW) performance on galvanized and coated steels.

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Welding rolled pipe in the 1G position efficiently

July 12, 2005

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For welding in the 1G position (in which the tube or pipe rotates), solid wire is traditional filler metal. However, metal-cored wire is making headway as an alternative. Metal-cored wire requires no land at the bevel, is more forgiving of welding dirty metal, produces less spatter, and allows travel speeds up to inches per minute.

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The blades of Don Fogg—a cut above

June 14, 2005

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This 11.375-in. blade was forged from 1095 steel; the habaki* is made from 40 percent shibuichi, gold-plated nickel silver seppa, and Damascus tsuba.*See glossary at the end of the article for swordsmithing terms. Photo courtesy of Don Fogg.What is it about forged and polished steel sharpened to an...

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Metal on his mind

June 14, 2005

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Most people are happy just to get their thoughts down on paper. Mike Ingram takes it a step farther, capturing what he sees in his mind in the metal he shapes and welds.

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Considering change

May 10, 2005

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Gas-shielded flux cored arc welding (FCAW) is known for its high deposition rates and out-of-position welding capability in heavy manufacturing and fabrication applications. In an industry often averse to change, many companies consider their current FCAW practices and equipment as trustworthy family members: always reliable, with no reason to change.

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MIG welding tips and resources

April 11, 2005

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Photo courtesy of AlcoTec Wire Corp.Motorcycle- and hot rod-building shows on TV have put welding in a very positive light lately. In fact, Jesse James, the star of Discovery Channel's "Monster Garage," was named the American Welding Society (AWS) Welder of the Year because of his contributions to...

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Using AC for Al

April 11, 2005

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Figure 1Orbital gas tungsten arc welding (GTAW) has been used in many industries since its introduction in the 1950s. Developed by the aerospace industry for welding small fittings to tubes, the process was limited by its large power supplies and cumbersome fixtures suited only to workshop...

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99% GTAW, 100% RAD

March 8, 2005

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Troy Trepanier stands next to the FastForward Fastback 1967 Mustang®, a project car restored with modifications borrowed from Ford's 2005 concept Mustang. It was made in 18 weeks with parts and accessories found and bought on eBay Motors. Troy Trepanier says his company does all the...

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Larger-than-life objects equal memorable sculptures

March 8, 2005

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Almost every artist blacksmith learns to make small animal heads from rods and often hammers petal-like shapes into flowers. But some 'smiths go far beyond these exercises and make items that are so much larger than life that they fall into the category of expressive sculpture.

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10 frequently asked GTAW questions

February 8, 2005

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Experienced welders know that without the right information, it's easy to sacrifice quality, lose time, and generally become frustrated with gas tungsten arc welding (GTAW). And while there is merit in learning by trial and error, if you want to move toward precision GTAW, getting answers to 10...

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More about MIG welding

January 11, 2005

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Editor's Note: This article is a companion piece to Marty Rice's article MIG welding—The basics and then some. My first time using MIG (also called gas metal arc welding, GMAW) in the field was working on four stainless steel hoppers (tanks) at an Owens Corning plant. X-rays of the hoppers'...

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Optimize your plasma performance

January 11, 2005

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Plasma arc welding (PAW) uses plasma, a gas that has been heated to a high temperature and ionized. The plasma becomes electrically conductive, transferring an electric arc to the workpiece through a small orifice.

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Weld repair—Analyze the failure before attempting the repair

November 9, 2004

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When something breaks, you acknowledge the shock, scratch your head, take stock of the situation, and look for the fastest way to repair the item and put it back into operation. The pressure to repair quickly is understandable, but common sense suggests stopping for a moment and trying to understand what caused the break before attempting the repair.

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A tribute to veterans

November 9, 2004

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Editor's Note: The U.S. remembers its armed forces' veterans twice each year— Memorial Day in May and Veterans Day in November. In this article, Marty Rice, a reader-favorite author on thefabricator.com, pays tribute to veterans and describes how one metal sculptor chose to represent an important part of a serviceman's or — woman's life.

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A Great Combination

September 14, 2004

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Dwarfed by his largest sculpture to date, artist Gary Beals collaborated with K-zell Metals to create this piece for the University of New Mexico.The stainless steel centerpiece for a grouping of sculptures at the University of New Mexico is a first for its creators for several reasons.First, the...

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