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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Tungsten electrodes

Selecting and preparing tungsten electrodes

January 15, 2008

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Selecting and preparing a tungsten electrode for welding involves choosing the correct electrode diameter, and prepping the electrode with the appropriate process and equipment. Successfully performing all three will allow for a consistent and stable arc.

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welder

Keeping consumables from consuming welding profits

January 15, 2008

Like every manufacturer these days, truck and trailer manufacturer Tico Manufacturing Inc. can't afford to waste any time on non-value-added activities. It recently switched its welders to Centerfire™ nonthreaded contact tips manufactured by Bernard®. These tips require replacement about once every two weeks; the previous tips were replaced three times a day. And because they are unthreaded, the tips take much less time to replace.

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Mountain image

Programmable lubricant application accelerates stamper's die changes

October 9, 2007

Red Rock Stamping, Chandler, AZ, airbag and seatbelt components manufacturer, looked for ways to improve its die change processes to handle the anticipated business volume increases. A lot of cleanup had been required around the machines as a result of the lubrication system. By installing a new fluid application system by UNIST, the stamper gained more control over the spray volumes and locations and reduced die change times. Fluid disposal was eliminated as well.

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Sub-assembly parts

New lube gives the slip to stamper's slips, trips, and falls

October 9, 2007

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KI USA, a division of KI Japan, stamps and produces sub-assembly parts for Toyota, Honda, Nissan, and other "transplant" automotive OEMs. The stamper wanted to improve plant safety by reducing incidents of slips and falls. Petroleum-based stamping lubricants that had been used created a slippery environment at the press and other sites. Changing the stamping lubricant system to a synthetic lubricant from MS Fluid Technologies not only improved plant safety and appearance, it produced cost savings and reduced the plant's impact upon the environment.

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GMAW welder

The tipping point

September 11, 2007

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Incorrect contact tip recess can cause excessive spatter, burn-through and warping, insufficient penetration, and porosity. Welders who become familiar with correct tip recess can avoid these problems as well as unnecessary equipment upgrades yet still improve GMAW quality.

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Arc welding shielding gases

Choosing shielding gases for arc welding

September 11, 2007

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Proper selection of the shielding gas for gas metal arc welding (GMAW), flux-cored arc welding (FCAW), and gas tungsten arc welding (GTAW) processes can dramatically improve speed, quality, and deposition rate of a given weldment.

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Flux cored wire and electrodes

Flood-weld forging dies and large castings

August 8, 2007

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COR-MET has been manufacturing flux cored wire and electrodes since 1972, specializing in high deposition alloys for the repair of Forging Dies and Large Foundry Castings. The Flood Welding Procedure will deposit up to 60 lbs per hour of weld metal. The consumable alloys available for Flood...

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Welder image

Beyond Commodity

June 12, 2007

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Before making a process change to metal-cored wires, it is important to establish a baseline to measure the potential for improvement, know the wire's capabilities, and be able to justify such a change.

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What's all the 'flux' about?

March 13, 2007

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Becoming knowledgeable about the different types of flux-cored stainless steel electrodes, what their capabilities are, how they are classified, and how to handle and maintain them safely can offer welders many benefits.

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Dam the purge gas and full speed ahead

July 11, 2006

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Shielding gas is an often overlooked area of savings in tube and pipe welding. Creating a purge dam in one of several different ways can help you isolate the weld area and minimize the amount of gas and time needed to purge the weld zone properly.

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Cracking the case

July 11, 2006

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Before welding abrasion-resistant plate, it's important to take certain precautions and choose the most appropriate filler metal for your application and weld metal.

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Examining the finer points of 6010, 6011, and 7018

June 13, 2006

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Knowing which rods tend to do what in the field can save you time and make for better results when the job is through.

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The need to feed aluminum

March 7, 2006

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While using aluminum can present challenges in any welding application, knowing the right questions to ask beforehand will help aid success. Issues include knowing what aluminum filler metal to use, how to store it, and what options are available to help eliminate feeding problems.

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Who you gonna call?

January 10, 2006

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Shopping around for a welding gases distributor involves several key issues critical to a successful long-term business-distributor relationship.

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Using flat wire in GMAW

November 8, 2005

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In manufacturing, new welding processes are being examined and tested while existing ones are being optimized. Specifically, conventional GMAW is evolving into a new process aimed toward helping fabricators and manufacturers realize increased productivity and economic viability. The use of flat wire is addressing one of the components of the process -- the electrode.

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