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Consumables Corner: The reasons for and misconceptions about preheating steel

June 10, 2014 | By Nino Mascalco

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 | By Nino Mascalco, Rob Koltz, Steve Sigler

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 | By Tony Anderson

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 | By Rob Centner

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 | By John Karpus

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 | By John Karpus

: 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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Corrosion-resistant fabrication project enhances nuclear power station’s cooling system - TheFabricator.com

Corrosion-resistant fabrication project enhances nuclear power station’s cooling system

September 6, 2013 | By Eric Lundin

Nuclear power plants use a lot of water to cool the reactors, and when the water intake unit occasionally pulls in a sea lion or a shark, environmentalists go nuts. Dimic Steel Tech bid on a contract to build two huge grates for Southern California Edison to keep marine life out of the water intakes, and had to learn a bit about welding corrosion-resistant steel along the way.

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Demystifying contact tips - TheFabricator.com

Demystifying contact tips

September 5, 2013 | By Rudy Simmons

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 | By David Benson

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 | By Brian Farkas

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 | By Robert Fox

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 | By Dan Davis

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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Handling, installing, and maintaining GMAW consumables - TheFabricator.com

Handling, installing, and maintaining GMAW consumables

October 20, 2011 | By Frank Laberi

For GMAW consumables in particular, several pitfalls exist that can shorten their life span. Taking the time to learn tips for keeping them clean and lasting longer can positively affect productivity, quality, and the bottom line.

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Handling, installing, and maintaining GMAW consumables - TheFabricator.com

Handling, installing, and maintaining GMAW consumables

September 12, 2011 | By Frank Laberi

For GMAW consumables in particular, several pitfalls exist that can shorten their life span. Taking the time to learn tips for keeping them clean and lasting longer can positively affect productivity, quality, and the bottom line.

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Jerry Mathison and Jay Ginder

Horizontal fillet test troubles

May 11, 2011

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...

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