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Lean manufacturing in producing square, retangular tubing

June 24, 2015

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Tube and pipe mills conventionally use a set of tooling for every tube or pipe diameter, and the tools are mounted to opposing stands. Cage forming provides an alternative forming process that uses a single set of tools.

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Fabricators flying ultralights

June 24, 2015

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Most people who own ultralight aircraft buy them fully assembled, but this isn't the only option. U-Fly-It, DeLand, Fla., lets the buyer be the builder if he's handy and has about two weeks to spare.

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New coil-applied nonmetallic coating protects press-hardenable steel

June 23, 2015

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Press-hardening high-strength steel is an important component in automotive construction to provide crash-worthiness. Several coating options are available today for use on stamped, press-hardened steel parts. However, none of these options are without limitations or challenges, such as cracking, coating transfer, fumes, weldability problems, and the need for shotblasting. A new coating technique has been developed and shows promise. The coating is a very thin (2- to 3-μm-thick), paint-like, rather than metallic, coating. It consists of a siloxane resin acting as the binder with aluminum flake to act as the sacrificial filler, so it meets the requirements to be inorganic and to contain a sacrificial oxidized material.

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When life hands you lemons, build a sign

June 23, 2015

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After the sign for his auto repair business fell off the building, Dominick Alia tried his hand at fashioning his own sign. One thing led to another, and metal sculpture became a hobby.

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Clamp, enclose, laser-weld

June 23, 2015

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Laser welding works extremely well, as long as you have the right enclosure, keep a clean environment, and make sure you have proper clamping to maintain a consistent gap between your base metals. One laser welding technology tackles all three of these challenges.

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Negative pressure yields positive results in resistance welding

June 23, 2015

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A system helps resistance welding lines save water as tip changeouts become more frequent. The technology uses negative pressure, similar to placing your thumb on top of a straw and lifting it out of a glass of water.

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How project management drives manufacturing success

June 23, 2015

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Manufacturing is no longer about making millions of this or that for years on end. It instead entails a team of experts who get together to tackle a project—or, in reality, many projects at once. This exemplifies modern metal manufacturing, and at Duggan Manufacturing, it happens every day.

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How basic training in lean manufacturing establishes a common view

June 23, 2015

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To ensure every employee has a common view of what’s ideal versus what needs to be improved, a few hours of basic lean training can go a long way.

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Technology Spotlight: Negative pressure yields positive results in resistance welding

June 15, 2015

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A system helps resistance welding lines save water as tip changeouts become more frequent. The technology uses negative pressure, similar to placing your thumb on top of a straw and lifting it out of a glass of water.

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R&D Update: Forming aluminum alloys at elevated temperatures, Part 1

June 11, 2015

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To reduce vehicle weight, automotive manufacturers are using advanced high-strength steels (AHSS) and aluminum alloys, formed at room temperature, as well as hot stamping of boron steels. A few OEMs and Tier 1 suppliers also have started warm forming aluminum alloys, usually 5000 and 6000 series,...

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Using cored wire in submerged arc welding applications

June 11, 2015

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Like all arc welding processes, submerged arc welding (SAW) requires the right consumables for the specific application to achieve optimal results. Are cored wires right for yours?

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Die Science: Slug pulling—Causes and solutions

June 11, 2015

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Slug pulling in a stamping die can be costly and frustrating. One pulled slug can cripple production. What Is Slug Pulling? When a pierce punch creates a hole, it also produces scrap, called the slug. When the slug sticks to the face of the punch during withdrawal or comes out of the button...

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Ask the Expert: Upfront spending reaps long-term savings

June 10, 2015

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Q: The cost of building new progressive dies has gone up substantially in the past few years. I am struggling, and in many cases lose money, on my tool builds. How is the industry expected to cope? A: This is a common problem throughout the metal stamping arena. It’s not easy to remain...

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When It Pays to Spend

June 9, 2015

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Specialized press brake tooling increases productivity, reduces operator fatigue, solves problems

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A waterjet pump primer

June 8, 2015

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Knowing the basics of waterjet pumps allows a fabricator to figure out just what technology makes sense for the work on the shop floor and just what type of commitment is necessary to run that pump technology successfully.

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