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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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Shop technology and 3-D CAD: Legends and Logos

June 23, 2014

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Columnist Gerald Davis investigates the CAD jockey’s role in the creation of markings on metal products, the different ways that these markings can be created, and some tips for ensuring the final marking is done correctly, no matter the process.

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Cooking up fabrication with the fiber laser

June 23, 2014

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Atlanta Custom Fabrication focuses on the commercial kitchen industry, mainly cutting thin stainless. Its laser cutting wasn't a constraint process, but it needed excess cutting capacity to deal with demand variability. A new fiber laser has helped to resolve the problem.

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Consumables Corner: Reducing weld cleanup in pulsed GMAW

June 20, 2014

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Q: Our company manufactures the main structures used to build fitness equipment. These structures are mild steel tubing of various shapes and sizes and in relatively thin material, typically 10 to 16 gauge. We are using 90 percent argon/10 percent CO2 shielding gas with a 0.035-in.-dia. ER70S-3...

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FAB 40: Merrill Fabricators’ welding school fuels local talent base

June 19, 2014

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Merrill Fabricators takes an innovative approach to the skilled labor crisis, by launching and growing its own welding school not only to fill its own ranks, but also to help grow the broader manufacturing community.

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Consumables Corner: Eliminating porosity in submerged-arc welding

June 19, 2014

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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...

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