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Arc Welding 101: Plugging holes and pinholes

May 12, 2015

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Q: I am machining a bearing housing made out of 1045 and I have to plug and weld some cross holes. I am also using gas tungsten arc welding (GTAW) to eliminate a weld that is too large. My problem is that I am getting pinholes in my weld. Is it because I am welding 1018 to 1045? We didn’t machine...

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Replica cars? There’s a kit for that

May 12, 2015

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A component (kit) car manufacturer in Wareham, Mass., made two big process changes that helped streamline its manufacturing operations.

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Consumables Corner: Eliminating weld cracking in restrained joints on high-strength steel

May 12, 2015

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Q: We're a construction equipment manufacturer that is finding that our customers increasingly require more components designed and manufactured from high-strength steels such as A514 or 4130. This means we have to preheat and follow slow cooling conditions, but even then certain joints or...

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Aluminum Workshop: What to know when changing shielding gas with pulsed GMAW

May 12, 2015

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Q: Recently I bought a new high-end pulsing power supply, which has different modes for all of the common materials and wire diameters. I was getting great results with 3/64-in. 5356 wire and 100 percent argon shielding gas. When I changed to a mixture of 70 percent argon/30 percent helium, the arc...

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Troubleshooting CNC plasma cutting, Part II

May 6, 2015

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The four most common cut quality issues for fabricators are dross, edge angularity, material warpage, and metallurgy of the plasma-cut edge. Your ability to achieve the best results depends on the system, torch, and consumables you are using, as well as the accurate control of such highly critical parameters as pierce height, cut height, amperage, gas type and flow rate, and cut speed.

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Best practices for welding aluminum

May 1, 2015

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Don’t wait for defects to appear in your aluminum welds. Be proactive by understanding how to prevent them from happening in the first place.

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Metallurgy Matters: Influencing weld strength

April 24, 2015

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Weld metal strength: It’s a subject that’s often discussed, and just as often misunderstood. To fully consider how strong weld metal will be or how you can strengthen it, you have to think about not only the preweld decisions that influence weld strength, but also the postweld reactions and...

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Building a winning motorsports weld shop

April 7, 2015

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Jeremy McGrath, a Supercross racer making the transition to off-road truck racing, recently set up a state-of-the-art motorsports welding shop geared toward component builds and repair work. If you’re setting up a motorsports welding and fabrication shop for the first time, there are some vital pieces of equipment that will help you be successful. It’s important to remember that you don’t have to be a renowned off-road truck racer to have a professional-grade motorsports fabrication shop.

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Metallurgy Matters: Reactions speak louder than words

April 6, 2015

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Before we get into nonferrous gas-metal reactions, let’s look at one of the ways you can identify potential cold-cracking problems in steel. In the May/June 2004 issue, we looked at cold cracking—also known as hydrogen cracking, delayed cracking, and under-bead cracking—as it relates to...

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Stainless Steel Workshop: Storing and reconditioning filler metals

April 6, 2015

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For years fabricators have questioned the need for properly storing opened containers of electrodes in a controlled environment. The cost of holding ovens, as well as the discipline required to use them, has had fabricators second-guessing the benefits of such a practice. Regardless of the type of...

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Fabricating for the win

March 26, 2015

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What does it take to make it in this ultracompetitive world where your work is heavily scrutinized, your time is not your own, and all the while you have a driver’s life in your hands? It requires incredible skill, yes, but there are other qualities you must possess and things you must accomplish. To be successful at one of racing’s top teams requires more than just welding ability. It requires an unparalleled dedication to the sport and to your craft. With that dedication, however, sometimes comes sacrifice.

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Stainless Steel Workshop: Weldability of ferritic stainless steels

March 23, 2015

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Q: What filler wires are best-suited for welding ferritic stainless steel? A: Automotive exhaust systemand component manufacturers such as ArvinMeritor, Benteler, Faurecia, and Delphi have welded ferritic stainless steel for years. Their choice of filler metal, either a 409 or a 439, provided a...

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Stainless Steel Workshop: Stainless steel production certification

March 23, 2015

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There continues to be confusion in the marketplace about the conformance standard fr the various classifications of stainless steel products. The American Welding Society establishes guidelines to which manufacturers must conform depending on the specification. However, within the specification,...

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Stainless Steel Workshop: Ferritic stainless steels

March 20, 2015

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Q: What are the advantages of ferritic stainless steels? A: When a fabrication requires corrosion resistance and high performance, your foremost concern is its affordability. One metal that can meet this demand is ferritic stainless steel. Grades include AISI type 409, 11CfCb, 430, 436, 439, and...

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Stainless Steel Workshop: Controlling Corrosion

March 20, 2015

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Q: How do I control corrosion in stainless steel? A: Corrosion in stainless steel is one of the most troublesome technical concerns for fabricators. Whether localized or widespread, corrosion takes many forms, depending on the particular service environment. Some common types are general...

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