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: Identifying pockmarking causes in structural SAW

June 16, 2014

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Q: Our company manufactures various structural components, typically made from A36 or A572 steel grades in plate, I-beam, or channel. Based on the application we’ll use GMAW, FCAW, or SAW. On random occasions we experience pockmarking on the surface of the SAW joints. While the timing is usually...

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Consumables Corner: The thought process behind changing a weld process

June 13, 2014

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Q: Our company is using 0.045-in.-dia. mild steel solid wire for GMAW with 90 percent argon/10 percent CO2 shielding gas. A majority of our base metal is ¼ to 1 in. thick welded out of position about 30 percent of the time. We are considering a change in our welding process to reduce lead-times....

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Consumables Corner: Tackling root penetration problems

June 12, 2014

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Q: We are experiencing weld root penetration issues in our single- and multipass welds. Our base metal is A36, and we oxyfuel-cut it in thicknesses from ½ to 3 in. Most of the weld joints are standard T-joints with a few groove joints. We are using a 0.045-in.- dia. E71T-1C/M flux-cored wire with...

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Consumables Corner: Examining the root cause of distortion

June 11, 2014

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Q: We manufacture hydraulic cylinders. Ever since we changed our shielding gas blend, we’ve noticed a higher level of distortion. Before the change we used a 95/5 blend, but now we use 92/8, which we have documented using a 0.045-in.-dia. filler metal. Would the 92/8 blend run hotter and cause...

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Consumables Corner: The reasons for and misconceptions about preheating steel

June 10, 2014

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Q: We are expanding our job shop and adding the capability to work with much heavier structures, including considerably thicker materials. Some of these jobs specify high-strength materials and preheating. Some of our welders claim preheating is performed to remove water from the steel. Can you...

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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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What's up with helium for welding applications?] - TheFabricator.com

What's up with helium for welding applications?

December 3, 2012

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Helium has been hard to get for some, and certainly the consumable gas is more expensive for welders than it used to be. The bad news is that this may be the case for some time. The good news is that alternatives are under development to help welders out as they tackle aluminum and stainless steel welding.

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