June 30, 2014
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.
June 18, 2014
Dominique Martinez, founder of Rustic Steel Creations, does a little of everything—using found objects and new metals, making functional items like handrails and decorative items (artistic sculptures), making items for sale and working under contract, working for profit and donating pieces for fundraisers—and in doing so, has built his company into a multimillion-dollar enterprise.
June 16, 2014
Native Texan and farmer Aggie Devin Gerland earned a degree in agricultural engineering and took a succession of engineering positions in and around Bryan, Texas. Now an entrepreneur with his own fabrication shop, Gerland is putting his farming and ranching experience to work, developing his own line of farm implements.
June 9, 2014
The manufacturing standards for manufacturing and fabricating tube and pipe are continuously on the rise as OEMs demand tighter tolerances and ever-greater dimensional consistency. Keeping up with these trends is a matter of keeping up with the technologies available to monitor processes and measure tubular products.
June 2, 2014
The welders at JATCO Environmental Inc., a manufacturer of steam-to-liquids condensers for natural gas extraction, had a problem with striking and maintaining a good arc. When the company switched from a rectifier-based unit to an inverter-based unit, the welders found that the arc starts and weld characteristics were greatly improved.
April 21, 2014
Texas is known for two or three commodities, namely cattle, oil, and barbecue, but the state has plenty of manufacturing, too. It’s a good environment for a fabricator and an entrepreneur with the imagination to come up with new products and build prototypes, regardless of the industry or market. Devin Gerland, found of JackRabbit Manufacturing, is one such entrepreneur.
April 14, 2014
Freedman Seating Co., founded in the late 19th century, originally manufactured seat cushions for horse-drawn buggies. As gasoline engines displaced animal power, Freedman adapted and today uses the latest technologies, such as CNC tube benders and a laser cutting machine, to stay current with trends in transportation.
March 31, 2014
Prototyping a roll formed profile doesn’t have to be done in the conventional way, with hardened tooling and short runs made from long strips of material (or coil). American Roll Form uses butt-welded strips of steel, fed into a roll former outfitted with soft tooling, to prototype roll-formed sections. It uses a few other strategies that substantially reduce prototyping cost and lead-time.
March 14, 2014
O’Neal Steel, founded in 1921 in Birmingham, Ala., originally was a fabrication shop, and the founder later added metal distribution to the company’s repertoire. Over the decades the business model changed, fabrication disappearing altogether at one point. Eventually the company resurrected its fabrication arm, but one thing has been a constant: The company’s small-town, close-knit, neighborly culture.
March 14, 2014
A typical bending machine process is feed-bend-feed-bend, or maybe feed-bend-feed- rotate-bend, until the feedstock is used up. However, this isn’t the end of the fabrication process, which includes a subsequent cutting step. The cut often means waste, especially for short-length parts, and the problem is compounded when the volume is high or the material is expensive. Read about how one bender manufacturer changed the process to feed-bend-separate-feed-rotate-bend-separate.
March 3, 2014
It’s no secret that Düsseldorf’s biennial tube and pipe expo, TUBE®, is a good way to gauge the industry’s health. The expo is 3 percent larger in 2014 than it was in 2012, and the exhibitors interviewed for this article expect good things from the industry in the coming year. These in-depth perspectives also revealed that upheaval in the U.S. energy industry is leading to changes that will have repercussions for decades.
February 24, 2014
Lean manufacturing may have once been little more than a buzzword, but it is way of life for many in the metal fabrication industry. Meanwhile, the pursuit of quality is as critical as ever. Conference facilitators and participants discussed how these can go hand-in-hand at the 2013 EDTR roundtable event, Lean Manufacturing and the Quality Imperative, Sept. 15-17, Silverton, Ore. The outcome was a series of stories and tips that any fabricator could use to run leaner and maintain a quality product.
February 17, 2014
Tube and pipe producers are familiar with ultrasonic testing (UT) which, as the name implies, uses high-frequency sound waves to find discontinuities in tube and pipe. While conventional UT is effective for testing raw materials with simple shapes—round tubing, rectangular billet, and rectangular plate—complex shapes such as castings and assemblies need something more. Phased-array ultrasonic testing (PAUT) gets the job done.
February 14, 2014
February 14 is here again, and although the origin of St. Valentine’s Day is a little weird, it’s hard not to miss the staying power of this celebration. Originally a pagan fertility rite celebrated in ancient Rome, Lupercalia was later co-opted by the church as Christianity took hold, and...
February 10, 2014
Although oil extraction around the world has grown by 50 percent in the last 30 years, it was basically flat in North America until 2008. Higher oil prices have made tar sands oil economically viable, and new extraction techniques have been a boon to U.S. producers. Interviews with a variety of vendors in the forming and fabricating industry reveal the many trends that are driving changes in the equipment and supplies used in the petroleum business.