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541 results

1+1+1+1 = Clarity

January 21, 2015

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Selecting a helmet involves more than just pulling one off of a shelf, putting it on, and getting to work. A number of considerations come into play during the selection process — personal safety, wearer comfort, and optical clarity. The latter has moved from something hard to determine without guesswork to something that has true quantifiable benchmarks with the advent of the European Standard EN 379 1/1/1/1.

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Consumables Corner: Causes of centerline cracking in FCAW root passes

January 20, 2015

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Q: We are a bridge and structural steel manufacturing shop that uses a mixture of common base materials such as A36, A572, and A992. Recently we’ve been experiencing sporadic centerline cracks in the root passes of fabricated I-beams that we weld with flux-cored arc welding (FCAW). Oddly enough,...

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Arc Welding 101: Put your finger on it

January 20, 2015

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Q: I'm a welding instructor at a steel mill in northwest Indiana. We attended the “Train the Trainer” class at the Hobart Institute of Welding Technology 12 years ago to certify in all positions, limited and unlimited thickness plates with backing, using all shielded metal arc welding (SMAW)...

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Aluminum Workshop: Why it’s so hard to weld anodized aluminum

January 20, 2015

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Q: I bought some anodized 6061-T6 tubing to make a structural framework and I’m having trouble welding it. The welds are black and ugly. Can you help? A: I think I can help. First, it would be helpful to explain what anodizing is. Anodizing is a reverse plating operation of sorts in which the...

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Fabrication minus the relaxation

January 15, 2015

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No-niche southwest Florida fabricator grows big in small time frame

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Aluminum Workshop: Welding 6061-T6 without filler metal; choosing shielding gas for GMAW

January 6, 2015

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Q: I’m trying to use gas tungsten arc welding (GTAW) without filler metal to join 6061-T6, and almost every weld I make cracks. What’s going on? A: A common aluminum alloy, 6061-T6 is welded every day, so we assume it must be easy to weld. Unfortunately, it isn’t. In fact, 6061 and the other...

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Aluminum Workshop: Welding anodized 6061-T6 extruded tubing, 7075 series aluminum

January 6, 2015

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Q: I bought anodized 6061-T6 extruded tubing and have been trying to gas tungsten arc weld (GTAW) if, but the results so far haven’t been satisfactory. The welds look black and porous. I’m an experienced welder, and I’ve welded aluminum before, but I’ve never run into this. Is there...

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Aluminum Workshop: Choosing an aluminum alloy

January 5, 2015

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Q: I have a project I want to build from aluminum sheet and extrusions. Some of my friends tell me to make it entirely from 6061-T6. Other tell me to use other alloys, mostly 5000 series. The project entails a lot of welding. Which alloy should I use? A: Without knowing more details about your...

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Aluminum Workshop: Defining cast and helix

January 5, 2015

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Q: What are cast and helix? I keep hearing about them, but no one seems to really know what they are. A: First of all, cast and helix are two separate attributes of spooled wires intended for gas metal arc welding (GMAW). The terms have no meaning for straight cut lengths of wire meant for gas...

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Aluminum Workshop: Understanding AC and HAZ ‘cracks’

January 2, 2015

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Q: I know that when aluminum alloys are gas tungsten arc-welded (GTAW), usually we use alternating current (AC) because it give some sort of cleaning action. Can you explain what it is and how it works? A: Sure, let’s try. But before I start, let me admit that this explanation is a bit of a...

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Aluminum Workshop: Defining arc rectification

January 2, 2015

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Q: Sometimes when I’m AC gas tungsten arc welding (GTAW) aluminum, the arc will start to flutter for a while. I can see it and hear it. Usually it goes away after a few seconds. What’s going on? A: First of all, the good news is that you’re not imagining it. This phenomenon is fairly common...

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Aluminum Workshop: Using 4043 versus 4047 filler wire

December 30, 2014

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Q: I usually use 4043 filler wire for welding 6061-T6 and castings. My friend told me I should switch to 4047 because it’s stronger. Is that true? It’s more expensive than 4043. Is it worth it? A: As you know, 4043 and 5356 are the most common aluminum filler alloys. In fact, these two alloys...

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Aluminum Workshop: Cleaning aluminum before welding

December 29, 2014

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Q: What’s the best way to clean aluminum before welding? How long can I wait to weld it before it needs to be cleaned again? A: Preweld cleaning requires two operations: oil and grease removal and oxide removal. Before you do anything else, remove any oil, grease, or water vapor from the...

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Aluminum Workshop: Fabricating aluminum plant boxes

December 29, 2014

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Q: I am bidding on a job to fabricate aluminum plant boxes. They will sit inside 4-foot-tall walls in an office. These rectangular boxes, or troughs, will be 7.5 inches tall, 7.5 in. wide, and 48 in. long, placed end-to-end to form 16-ft. dividers. I plan to use 5052 aluminum. A 1.75-in. flange,...

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Aluminum Workshop: Passing tensile tests for 6061-T6

December 26, 2014

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Q: I am having problems passing the tensile tests for my procedure qualification of aluminum alloy 6061-T6 on 6-inch-diameter pipe, Schedule 120. I am using ER4043 filler metal for a gas tungsten arc welding (GTAW)-gas metal arc welding (GMAW) combination process on the first joint and ER5363 on...

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