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Consumables Corner: Advancements in SAW

August 29, 2014

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Q: What role does flux and wire play in submerged arc welding? A: It is important to choose the right flux and wire combination for submerged arc welding (SAW) processes. This will allow you to gain efficiency while meeting your performance requirements. Basic submerged arc welding uses a single...

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Arc Welding 101: Achieving a good work lead connection

August 29, 2014

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Q: What makes a good ground connection, and why is it important? A: In a welding circuit, current needs to pass through as few connections as possible, and the circuit itself needs to be as short as is practical. On the positive (+) side for gas metal arc welding (GMAW), direct-current electrode...

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Consumables Corner: Eliminating porosity on galvanized steel

August 28, 2014

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Q: Our company manufactures storage rack systems made from mild steel and galvanized tubing. A majority of our parts are fixture-welded on a robot using 0.045-in.-diameter ER70S-6 wire with 90 percent argon/10 percent CO2 shielding gas. We have experienced problems with weld appearance quality and...

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Arc Welding 101: Reading between the lines of AWS D1.1

August 27, 2014

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Q: I am a weld inspector and one of my clients builds control panels. A potential customer of theirs requested that they conform to AWS D1.1 standards on a control panel. This seems odd to me. Can a company become AWS D1.1-certified? Is there a certain process they have to go through to become a...

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Consumables Corner: Changing over to metal-cored wire in SAW

August 27, 2014

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Q: One of my vendors recently approached me about replacing the solid wire in my submerged arc welding (SAW) application with a metal-cored wire. Should I consider making the change? A: Depending on your application, you should certainly consider making the change. Metal-cored wires can provide...

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Consumables Corner: Lowering weld hardness in SAW

August 26, 2014

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Q: We manufacturer dual submerged arc welded (DSAW) pipe for API use. Some jobs require that the weld hardness be below 250 Vickers. We are having trouble meeting that requirement. What can we do? A: Weld hardness restrictions generally are found in pipelines designated for sour service and are...

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Consumables Corner: Choosing a filler metal supplier with critical welds in mind

August 25, 2014

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Q: What should we look for when choosing a filler metal supplier for critical welds, such as those in the power generation industry? A: For critical applications, you need to find a supplier with a long track record in understanding the needs, developing products, and creating solutions for that...

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Consumables Corner: Selecting filler metal for robotic welding

August 22, 2014

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Q: We are just getting started in robotic welding. What advice can you give us on how to select the correct filler metal? A: As in any high-productivity application, the main consideration in selecting a filler metal for robotic welding is performance consistency. You want a wire that will...

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Consumables Corner: Storing stick electrodes

August 21, 2014

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Q: I recently saw a comment that regular stick electrodes could be overdried in ovens to the point of causing poor weld performance. Is this true? We store all our electrodes, including low-hydrogen, at 135 to 140 degrees F at all times and have not noticed any problems. We are located in Arizona,...

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TIG welding: When looks matter

August 18, 2014

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Every GTAW bead tells a story. Learn how to identify what your weld bead says and make adjustments to amperage, travel speed, and consumables to ensure your GTAW bead tells the story you want it to.

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Getting Automated: Transitioning from hand-held to CNC plasma cutting

July 28, 2014

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Transitioning from the manual plasma cutting process to CNC plasma cutting process might seem like a daunting task. However, if you enter into the process prepared and with the facts, you’ll find that the switch can be relatively painless and one that can help grow your business.

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

July 16, 2014

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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

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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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Hope dies last

July 9, 2014

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A hard-nosed welding instructor at a medium-security prison in rural North Carolina gives his students discipline, confidence, a foot in the door to a trade, and the possibility for a new life upon release.

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

July 9, 2014

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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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