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.
June 19, 2014
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...
June 18, 2014
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...
June 17, 2014
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...
June 16, 2014
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...
June 13, 2014
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....
June 12, 2014
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...
June 11, 2014
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...
June 10, 2014
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...
June 5, 2014
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...
May 19, 2014
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.
April 7, 2014
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.]
September 9, 2013
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.
September 9, 2013
: 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
September 5, 2013
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.
June 28, 2013
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.