Consumables

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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American Weldquip establishes new website

July 21, 2014

American Weldquip Inc., a manufacturer of semiautomatic and robotic GMAW torches and peripherals in Sharon Center, Ohio, has launched a new website at www.weldquip.com. The new site features improved navigation and functionality. Visitors can access owner’s manuals and technical documents,...

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Nickel-based GMAW/GTAW wire resists oxidation

July 16, 2014

Lincoln Electric has introduced Techalloy® X, a new nickel-based GMAW and GTAW wire that resists oxidation and provides high-temperature strength. The welding wire is suitable for petrochemical applications, providing enhanced stress corrosion cracking, and for aerospace applications that are...

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Consumables Corner: Examining weld cracking, Part II—Stress, hydrogen cracking

July 16, 2014 | By Jay Ginder, Jerry Mathison

Editor’s Note: This is the second column in a two-part series. Q: I work in a midsized job shop, and we weld with the FCAW, GMAW, and SMAW processes. Occasionally we encounter weld cracking issues. What causes weld cracking, and what can I do to prevent it? A: Stress cracking is similar to hot...

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Consumables Corner: Examining weld cracking, Part I—Hot cracking

July 15, 2014 | By Jay Ginder, Jerry Mathison

Editor’s Note: This is the first article of a two-part series. Q: I work in a midsized job shop, and we weld with the FCAW, GMAW, and SMAW processes. Occasionally we encounter weld cracking issues. What causes weld cracking, and what can I do to prevent it? A: To ensure that the measures you...

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Boot design encapsulates electrical connection between weld torch, cable

July 14, 2014

Victor Technologies™ has introduced a new boot design on its Victor® Arcair® Angle-Arc series of torch and cable assemblies that encapsulates the electrical connection between the torch and weld cable and eliminates the chance of accidental arcing. The patent-pending, two-piece boot design is...

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Fume extraction gun made to be lightweight

July 10, 2014

Bernard has redesigned its Clean Air™ fume extraction gun to be lighter and smaller than many standard fume extraction guns. With nearly the same dimensions as the company’s regular semiautomatic GMAW gun, it is suitable for almost any medium- to heavy-duty solid or flux-cored welding...

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Consumables Corner: Selecting the correct diameter for flux-cored wire

July 9, 2014 | By Jay Ginder, Jerry Mathison

I work in a large manufacturing fabrication shop where we weld subassemblies and then fit and weld them together to complete the machines we manufacture. Currently we use gas-shielded, flux-cored wires from 0.045 to 0.09375 in. in diameter. At what point is a small-diameter wire too inefficient,...

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Consumables Corner: Combating overheating in work clamps

July 8, 2014 | By Jay Ginder, Jerry Mathison

Q: I weld in a large pressure vessel shop and use many welding processes, including SMAW, GMAW, FCAW, and SAW. Regardless of the process, our work clamps always get very hot. We’ve even had some arcing from the ground clamp. We have welded several grounds to the workpiece to remedy this problem,...

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Consumables Corner: Combating dull weld appearance with metal-cored stainless steel wire

July 7, 2014 | By Jay Ginder, Jerry Mathison

Q: We fabricate 401 stainless steel components and have considered using metal-cored stainless steel consumables. One of the issues with metal-cored consumables is the dull appearance of the weld compared to the appearance achieved with a solid wire. What can we do to maintain a clean or shiny...

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Consumables Corner: Nixing porosity during weld start

July 3, 2014 | By Jay Ginder, Jerry Mathison

Q: I work for a job shop that fabricates and welds process piping for various applications. The pipes, made from A106-88a carbon steel and 304 and 316 stainless steel, are welded using GMAW, FCAW, and GTAW. We have been experiencing porosity, primarily on the weld starts. Our shielding gas is a...

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Consumables Corner: Welding heat treatable steels

July 2, 2014 | By Jay Ginder, Jerry Mathison

Q: Our shop won a contract that requires welding 4130 steel. I’ve been told this is a heat-treatable steel. Can you tell me which different welding procedures have to be used to weld this material? A: The most commonly welded heat-treatable steels are 4130, 4340, and 8630. However, any steel...

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Consumables Corner: Horizontal fillet test troubles

July 1, 2014 | By Jay Ginder, Jerry Mathison

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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Seamless wires resist moisture pickup

June 30, 2014

Hobart Brothers Co. has introduced new seamless flux-cored and metal-cored wires designed to offer extreme resistance to moisture pickup and minimize cracking. The new Hobart® MEGAFIL® wires also have less than 4 ml of diffusible hydrogen per 100 g of weldment, which further mitigates cracking...

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Consumables Corner: Welding weathering-grade material with a nickel-containing filler

June 27, 2014 | By Jay Ginder, Jerry Mathison

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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Consumables Corner: Issues with incomplete fusion

June 27, 2014 | By Jay Ginder, Jerry Mathison

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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