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Underwater aluminum GMAW
Article
May 3, 2013
While welding aluminum on dry land can be tricky, welding in an undersea environment vastly complicates the process. Early on in development of the new procedure, aluminum welds performed on the surface passed X-ray tests, but those made in... Read more... -
Surviving the storm
Article
April 24, 2013
Figure 1 Saltwater flooded Architectural Grille’s Brooklyn facility after Hurricane Sandy’s high-powered wind blew down a roll-down door. Photos courtesy of Architectural Grille. Architectural Grille was a company on the move... Read more... -
A welding robot--on the move
Article
March 7, 2013
Demand variability is an immutable fact of contract metal fabrication. A fabricator’s customer mix can change and, with it, the product mix. Because of this, the shop has to be ready for anything. To be competitive, many have rethought... Read more... -
Tube, pipe producer executes 3-phase improvement plan
Article
January 18, 2013
Since it was founded as a pipe distributor in 1979, Trinity Products, O’Fallon, Mo., has been expanding its horizons. It added fabrication services in 1986 and began pipe production in 2007. Trinity’s product portfolio includes 24- to... Read more... -
Succeed at welding thick aluminum with the right material preparation, filler choice, and equipment
Article
December 3, 2012
Begin with clean base and filler materials to avoid hydrogen contamination that causes porosity in the weld. Photo courtesy of AlcoTec Wire Corp. Aluminum is tough. It bullies its way into welded applications traditionally filled by... Read more... -
Aluminum MIG
Article
May 25, 2012
Making a commitment to putting together a topnotch, aluminum-friendly system—from equipment and setup to material preparation and welder education—are more likely to succeed than those who do not. Photo courtesy of Fronius USA LLC.... Read more... -
New year, new welding helmets
Article
February 1, 2012
3M Occupational Health and Environmental Safety Division There’s no better way to usher in the new year than to evaluate your safety equipment to make sure everything is in topnotch working order. One of the most important pieces of... Read more... -
Fabricating tight ships on a tight deadline
Article
February 1, 2012
Figure 1 Welders at Great Lakes Shipyard used a pulsed, inverter-based power source and solid aluminum wire to weld the aluminum hull. When the U.S. Geological Survey (USGS) approached Great Lakes Shipyard in Cleveland in June... Read more... -
Consumables make a difference in the welding of wind towers
Article
September 9, 2011
Figure 1 This large wind tower—with blades that are 164 feet long when measured from the center of the hub—sits on Lincoln Electric Co.‘s campus in Cleveland. It is considered to be one of the largest wind towers installed in an... Read more... -
Weldable and unweldable aluminum alloys
Article
May 11, 2011
I want to weld on some 7075 aluminum, but I can't find a recommended filler metal for it. Can you tell me the correct filler metal to use? In a word, no. The reason you can't find a recommended filler metal for 7075 is that it is usually... Read more... -
Achieving T6 designation for 6061
Article
March 14, 2011
Let's first describe what is happening when you heat treat 2XXX, 6XXX, or 7XXX alloys. All of these alloys are heat treated by precipitation hardening. This involves two steps—solution heat treating and aging. Solution heat treatment is done... Read more... -
A feminine approach to PPE
Article
January 10, 2011
Women welders want jackets, gloves, and boots that fit them, allowing them to work efficiently and safely, said welder/fabricator/television personality Jessi Combs. Choosing the road less traveled has always been more Jessi Combs’... Read more... -
FCAW-S basics: Fast, no gas cylinders required
Article
December 3, 2010
Figure 1 Self-shielded flux-cored arc welding is used often for out-of-position work. Self-shielded flux-cored arc welding (FCAW-S) wire is the industry’s multitasker. All at once it produces its own shielding to help protect the... Read more... -
Tackling aluminum GMAW
Article
November 22, 2010
Technology advancements in GMAW power sources have made tackling aluminum welding challenges easier by providing a balance of high travel speeds with a narrow, focused arc under a protective inert gas barrier. The reactive nature of... Read more... -
Wire welding in the structural steel world
Article
June 1, 2010
For many years structural steel fabrication has been dominated by shielded metal arc welding (SMAW). Technology advancements to flux-cored arc welding (FCAW) have helped fabricators like Hot AZ Hell Welding and Fabrication, Chino Valley,... Read more... -
Beyond low-carbon steel
Article
March 1, 2010
Figure 1 Certain alloys, such as the high-carbon steel used in this caster roll, require sufficient preheat, which slows cooling after welding and helps prevent cracking. The economy has pushed fabricators to adapt, market themselves to... Read more... -
No cracking under pressure for pipeline contractor
Article
November 3, 2009
Figure 1 Traditionally, welders working with the SMAW process used low-hydrogen electrodes and welded vertical-up. New electrodes, however, enable welding to be done vertical-down, a much more welder-friendly process that helps to... Read more... -
SMAW: A welder's guide
Article
September 15, 2009
Shielded metal arc welding (SMAW) is the most common form of arc welding. However, creating a good weld is not always easy, especially for a beginner. Unlike gas metal arc welding (GMAW), in which you basically point and shoot, SMAW requires a... Read more... -
Robotic GTAW or GMAW: No longer a clear-cut choice
Article
September 6, 2009
Figure 1 Technology advancements have made GTAW easier to automate. Photo courtesy of The Lincoln Electric Co. Robotic systems manufacturers and integrators have a confession when it comes to TIG, or gas tungsten arc welding:... Read more... -
SMAW: A welder's guide - Advice and troubleshooting tips for beginners
Article
September 1, 2009
Becoming proficient at SMAW takes practice and knowledge of a few helpful tips and troubleshooting techniques. Shielded metal arc welding (SMAW) is the most common form of arc welding. However, creating a good weld is not always easy,... Read more... -
Trends in offshore energy
Article
July 28, 2009
Although Hurricane Katrina lasted just seven days from start to finish, it was among the most destructive natural disasters in the history of the U.S. The flooding, damage to residential districts, displacement of residents, and loss of... Read more... -
Automating to grow
Article
May 1, 2009
Figure 1 G&W Products is in a good place during this downturn—with plenty of work on the floor G&W Products is in an unusual situation. It's growing. The Fairfield, Ohio, metal fabricator is on track to achieve... Read more... -
Building the bridge to anywhere
Article
April 1, 2009
To say that Stinger Welding Inc. is unique could be considered an understatement. After all, the AISC-certified fabricator of bridges and bridge components from Coolidge, Ariz., prides itself as a team whose very livelihood is to fabricate,... Read more... -
Age before welding in T6
Article
March 24, 2009
In the last Aluminum Workshop, you talked about improving the welded strength of 6061 by welding in the T4 temper and aging after welding. But what happens if we weld in the T6 temper and age after welding? Does the weld get stronger, or does the... Read more... -
Truckin' along
Article
November 25, 2008
Dump bodies start out upside down and are flipped after the sides are attached. Then the fronthead and tailgate, including hinges, are welded in place. Truck Bodies & Equipment International (TBEI), Eden Prairie, Minn., a fabricator of dump... Read more... -
Automating the Small
Article
September 16, 2008
Figure 1 Given the right parameters, welding robots can increase efficiency, even with the shortest part runs. My son got a haircut recently. He's a kid, so the barber didn't have to cut too much hair, but being 5, my son required... Read more... -
Submerged arc welding : then and now
Article
July 29, 2008
Submerged arc welding (SAW) is so named because the weld and arc zone are submerged beneath a blanket of flux. The flux material becomes conductive when it is molten, creating a path for the current to pass between the electrode and the... Read more... -
Auto weld that ends well
Article
June 17, 2008
The robotic welding cell Tommy Gate Co. installed two years ago has a footprint roughly 20 feet by 20 feet. Three years ago Peter Dunlop, production supervisor for Tommy Gate Co./Woodbine Manufacturing at the time, and Andrew Fitzgibbon, a... Read more... -
Preventing porosity in humid environments
Article
March 11, 2008
I'm having problems with excessive porosity when TIG welding aluminum. My friend says it comes from water vapor in the air (it's very humid here) being broken down by the arc. Is this true? It sounds pretty far-fetched. I hope you didn't bet on... Read more... -
Nothing standard about this fab shop
Article
February 12, 2008
After five years of working for a family-owned metal fabricating business in eastern Connecticut, Rob Marelli wanted to do things his way. He approached the president with an offer to buy the company from him, but he was soon gone with a... Read more... -
Vertical SMAW: It's a stick up
Article
January 15, 2008
Figure 1 SMAW, or stick welding, requires a certain mastery of skills, and vertical and overhead stick welding is that much more difficult-one of the reasons the specialty is in such great demand. Vertical and overhead stick welding have... Read more... -
It's a wrap
Article
January 15, 2008
It's no surprise that show organizers, attendees, and exhibitors alike are billing the 2007 FABTECH® International & AWS Welding Show as one of the best ever. If you were there, then you know why. If not, the numbers tell the story, albeit... Read more... -
Welding helmets in view
Article
January 15, 2008
Lincoln Electric's VISTA Choosing the right welding helmet is not as easy as it once was. Technology advances have turned these once simple pieces of protective equipment into smart, lightweight safety devices that, in some cases, can adapt... Read more... -
Up to speed
Article
November 6, 2007
NASCAR® roots run deep in the American Southeast. More than 50 years ago, atop sandlot racetracks with haystack walls, local thrill-seekers sought mere bragging rights behind the wheels of their modified family sedans. Today's racecars... Read more... -
Minimizing weld cleaning stripes
Article
September 11, 2007
I'm fabricating toolboxes for pickup trucks using gas metal arc welding (GMAW) and polished aluminum tread plate. The cleaning stripes along each side of the weld are wide and detract from the appearance of the toolbox. Please don't tell me to... Read more... -
To weld or not to weld Alclad
Article
July 10, 2007
I have some aluminum sheet that I would like to use to fabricate a project. The only marking on it is "Alclad." Other than that, I have no idea what alloy it is. Can you tell me what filler metal to use to weld it? Whether you realize it or not,... Read more... -
Extreme weld makeover
Article
July 10, 2007
Sfi, a large steel and aluminum fabricator with headquarters in Memphis, Tenn., and a second plant in Conway, Ark., manufactures industrial equipment components and subassemblies, from locomotive oil pans to crane outriggers, for large... Read more... -
Aluminum Workshop
Article
May 8, 2007
I have a fabrication project involving 5454 aluminum plate, and I was told to weld this alloy using 5183 filler wire. Is this correct? If you check any of the charts showing the recommended filler metals for the various aluminum alloys, you... Read more... -
Pressure to perform
Article
February 13, 2007
Like many large fabricators today, Ward Tank and Heat Exchanger Corp., Charlotte, N.C., has struggled to attract qualified welding operators to fabricate large pressure vessels, one of the company's principal products. The vessels are used to... Read more... -
Drive fast, weld right
Article
November 7, 2006
"Drive fast, turn left" may be a popular motto among race car drivers, but motorsports fabricators have their own: "Drive fast, weld right." A successful racing team is the sum of its parts, from the fabricators to the painters to the... Read more... -
New rule, new equipment
Article
November 7, 2006
A magazine article made Greg Faulkner think about improving welding ventilation at his workplace last year. Faulkner, senior manufacturing engineer at Henny Penny Corp., an Eaton, Ohio-based food service manufacturer, knew that the high... Read more... -
Which filler wire is best for welding 6061-T6 aluminum, 5356 or 4043?
Article
October 3, 2006
Both are acceptable for welding 6061-T6, but each has advantages and disadvantages depending on the application. An aluminum alloy containing 5 percent magnesium, 5356 generally is stronger and more ductile than 4043. But 4043, which contains 5... Read more... -
Little Giant takes flight
Article
September 12, 2006
Brian Nielson, an automated fusion technician with Wing Enterprises, operates one of the company's robotic welding workcells. Nielson said that moving to robotic welding has helped the company's productivity increase by 25 percent to 30... Read more... -
Hitting pay dirt -- in pipe
Article
May 9, 2006
72-in.-dia., 1-in.-wall pipe is being welded using preheating coils on each side of the weld. A torch bracket reaches over the coils. Oil refineries aren't the only ones hitting pay dirt in Canada. Northern Alberta is the land of... Read more... -
Staying grounded
Article
March 7, 2006
Grounding means much more than punishing your teenager by restricting his privileges. In welding, grounding is critical to arc welding safety. Various codes and standards document grounding electrical circuits as a safety practice. A... Read more... -
Making your way as a job shop today
Article
February 7, 2006
Karl Fischer says that staying flexible, within the skills you have to offer, has helped him keep his business successful over the years. Here, he stands next to a 304 stainless steel beer carbonation carboy that required internal pipe... Read more... -
Wading through the world of welding
Article
January 10, 2006
Many high-tech gadgets that once were handy extras are becoming indispensable in the workplace. A personal digital assistant (PDA) device makes programming a welding power supply faster and easier than manual programming. Photo provided by... Read more... -
Positioning your welds
Article
January 10, 2006
Robotic welding can improve your productivity, but its efficiency depends greatly on fixturing design and functionality. When applied properly, robotic welding can be economical; on the flip side, it can be inefficient and... Read more... -
Welding aluminum piping
Article
October 11, 2005
Aluminum piping is test-welded in a laboratory. A large number of fabricators manufacture carbon and stainless steel piping systems, and in general, the welding procedures and techniques for manufacturing them are well-known. But few... Read more... -
The most important welding lesson
Article
July 12, 2005
Whether you're a professional welder with extensive training, a self-taught welding hobbyist, or a welder in-between, you must learn and heed all welding safety precautions. If you don't, you're setting yourself up for a world of hurt, or... Read more... -
MIG welding tips and resources
Article
April 11, 2005
Photo courtesy of AlcoTec Wire Corp. Motorcycle- and hot rod-building shows on TV have put welding in a very positive light lately. In fact, Jesse James, the star of Discovery Channel's "Monster Garage," was named the American Welding... Read more... -
Site-based telemetry systems streamline gas supply
Article
October 12, 2004
Photo courtesy of TRUMPF Inc. Metal fabricators continue to find new applications for carbon dioxide (CO 2 ) lasers. New uses combined with increased just-in-time processing, and lights-out operation place greater demands on laser,... Read more... -
Laser-gas delivery systems for all applications, including 24/7 operation
Article
July 13, 2004
Photo courtesy of Weldstar, Aurora, Ill. Centralized System Advantages A centralized system allows all of the cylinders to be stored in one location. Having all cylinders in one place streamlines inventory control and simplifies and... Read more... -
Personality + Protection
Article
April 6, 2004
For welders, it's more important than ever to do more—perform more processes, know more about metals, be familiar with more welding situations—with safety equipment that can meet the requirements of every situation. At the... Read more... -
Efficient shielding gas supply methods
Article
February 26, 2004
In any welding process, the gas supply system must address basic equipment requirements for the gases at the point of supply and at the point of use. The type of shielding gas required determines the point-of-supply equipment needed, the mode in... Read more... -
Choosing the right oxyfuel gas and supply system
Article
November 6, 2003
Photo courtesy of Weldstar Inc. Cutting In oxyfuel cutting, an oxygen jet, not the preheat flame, performs the cutting. The oxygen jet oxidizes the material and expels the heated material from the kerf. The purpose of the preheat... Read more... -
Choosing a GMAW machine for occasional aluminum welding
Article
September 25, 2003
I want to buy a small gas metal arc welding (GMAW) machine, preferably one that runs from 120-V input power. Most of my welding will be steel, but I would like to weld aluminum occasionally. Can these machines really weld aluminum? I've heard a... Read more... -
Efficient use of compressed gases can increase productivity
Article
August 28, 2003
Photo courtesy of Harris Calorific Inc. GMAW and GTAW continued to grow in popularity with the introduction of lighter materials, such as aluminum and magnesium, in the late 1940s. Both of these processes use compressed... Read more... -
Inverter versus transformer power supplies for aluminum GTAW
Article
August 28, 2003
I'm looking for a new GTAW power supply for AC aluminum welding. I had intended to buy a conventional transformer unit, but several people have told me to buy an inverter-based power supply. Which one is better for my application?... Read more... -
Washington women weld at the 'Y'
Article
August 28, 2003
It's a drizzly, blustery Pacific Northwest morning in November with the gray light of dawn coming up behind the Cascade Mountain Range. Crew Leader Cheryl Boxx, clad in Carhartts®, squares her hard hat in place and begins checking... Read more... -
Welding aluminum with inverter-based power supplies
Article
July 24, 2003
Direct Current All welding power supplies transform relatively high-voltage, low-current incoming power to lower-voltage, high-current welding output using a transformer. In the past the transformer operated directly from 50- or... Read more... -
Which wire do you require?
Article
July 24, 2003
Many fabricators overlook the efficiencies they can gain by changing a wire or process. In fact, when you ask fabricators why they're using a particular electrode, some respond with "That's the way it's always been done here," even though... Read more... -
Al GMAW: CC or CV?
Article
June 12, 2003
I've read that constant-current (CC) power supplies are preferred for gas metal arc welding (GMAW) aluminum, but when I visit companies that sell welding equipment, they tell me I want a constant-voltage (CV) power supply. What's the real story?... Read more... -
How to recognize, minimize weld smut
Article
April 10, 2003
When I weld any aluminum alloy, I see a covering, light gray to black in color, over the weld. I see it when I gas tungsten arc weld (GTAW), but it's worse when I gas metal arc weld (GMAW). What is it? Does it affect the mechanical properties of... Read more... -
Choosing tungsten electrode type, size for aluminum GTAW
Article
February 27, 2003
I've heard different opinions about which size and type of tungsten electrode I should use to gas tungsten arc weld (GTAW) aluminum. Could you clear up this subject for me? As you know, we use direct current electrode negative (DCEN), or... Read more... -
KNOWLEDGE: The key to welding productivity?
Article
January 16, 2003
In the year 2000 manufacturing, construction, and mining industries had $34.1 billion worth of welding-related expenses. At the same time more than a half million people in the U.S. had welding-related jobs -- and that's not counting... Read more... -
Preparing, testing bend samples
Article
September 26, 2002
Almost all welding codes require bend tests for welding procedures and welder qualifications. These tests can cause more problems in aluminum than in steel. In bend testing, a 1 1/2-inch-wide sample is cut so the weld is running across the width... Read more... -
Set loose the juice
Article
September 26, 2002
Whether it means they're easier to use, more portable, or make welds more predictably, power sources are being updated, and electronics are playing a significant role in their modernization. "The current economy is forcing companies to... Read more... -
Embracing change
Article
July 25, 2002
It's been ages since horse-drawn carriages routinely transported passengers. In today's world, bypasses and interstates weave paths across the country, and many of the classic cars we see on the road are being carted from one classic-car show to... Read more... -
Beating the welder shortage, recession blues
Article
March 14, 2002
Skilled welders are hard to find. The economy is in recession. Production is down. And in the midst of these concerns, fabricators are concerned with welder safety. These issues are not new to welders and fabricating shops, but some say... Read more... -
GMAW vs. FCAW for beginners: Choose the best process for your small operation
Article
August 16, 2001
When you prepare to buy your first wire-feed welding machine, you don't want to waste your money on a toy that goes out with the trash in a few weeks. You probably want to use 115-V input for portability, but might want to step up to a... Read more... -
Preparing for aluminum GTAW
Article
April 24, 2001
Even if you are experienced in welding steels, aluminum welding can present quite a challenge. Aluminum's oxide coating, higher thermal conductivity, and lower melting point easily can lead to welding problems unless you know how to prepare... Read more...
