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Consumables Corner: Horizontal fillet test troubles

July 1, 2014

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Q: For a recently acquired large structural job, we have had to qualify a single-pass 5/16-in. fillet using 0.045-in. E71T-9M flux-cored wire. We are having trouble passing the horizontal fillet test. When performing the weld break test on the horizontal fillet weld, there is incomplete penetration...

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From looms to thermal spray to laser cladding

June 30, 2014

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Hayden Corp. has persevered over a century of change. It began as a supplier of wire cloth sold to the papermaking industry. Now it makes use of some of the most advanced surfacing technologies available.

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Cutting clean with 1-micron laser optics

June 30, 2014

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The high-brightness 1-micron cutting laser is redefining productivity in metal fabrication. The laser’s good absorption helps it cut faster with less power. It also means that keeping optics clean and dust-free is essential.

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Tube producer opens doors to new markets, controls costs with laser welding

June 30, 2014

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A niche tube producer that formerly used GTAW exclusively, Esta Rohr began changing over to laser welding in 2005. The change is now complete, with substantial changes. The company has reduced its number tube production lines from five to three, but its output has increased tremendously. Meanwhile, laser welding has allowed it to cut some costs, helping its products compete against others.

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FAB 40: Springs Fabrication and the ice house

June 27, 2014

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Springs Fabrication has humble beginnings, stereotypical of many successful American businesses. As it turns out, there's a reason that's a stereotype.

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Selecting a hydraulic hot-stamping press

June 27, 2014

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What makes a hydraulic press equipped for hot stamping? Access for auxiliaries and process equipment, a rapid deceleration rate, correct tonnage, and off-center load handling are all considerations.

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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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FAB 40: Thinking as owners at D&S Manufacturing

June 27, 2014

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At D&S Manufacturing, the books are open, employees know how to read them, and they use this information when dreaming up new ways to improve.

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Fab 40: Impulse Manufacturing tackles downtime with data

June 27, 2014

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You can't improve something you don't measure. Impulse Manufacturing wants to cut down the time between jobs—specifically, between the last good part of the previous job to the first good part of the next job.

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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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STIHL Inc. camp inspires youth to pursue manufacturing careers

June 23, 2014

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Think you might be interested in starting a summer camp to attract youth to manufacturing careers? STIHL Inc. did just that, found the endeavor worthwhile, and has even created a template for other companies to use in promoting manufacturing technology to youth.

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