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Only the clean survive
Article
March 1, 2013
Figure 1 Although the spot price for titanium has been known to exceed $12 per pound ($24,000 per ton), titanium components and assemblies often last longer and thereby have lower life-cycle costs than those made from other materials.... Read more... -
A road map for managing welding fume
Article
February 15, 2013
Figure 1 Implementing-source capture systems that immediately remove fume, as shown here, may eliminate the need for equpment such as personal respirators. Each welding operation has a different reason for weld fume management.... Read more... -
Invert the GTAW equation
Article
February 5, 2013
Modern GTAW inverter-based power sources are considerably smaller and lighter than their transformer-based counterparts, making them easier to fit in confined spaces. Classic transformer-style gas tungsten arc welding (GTAW) power... Read more... -
Growing in the face of uncertainty
Article
February 1, 2013
Figure 1 The management team that has helped to put A&E Custom Manufacturing on a consistent growth path includes (from left to right, starting in the front) Steve Hasty, owner; John Jaixen, general manager; Vicki Hasty, owner; Clark... Read more... -
Cutting the GTAW remote control cord
Article
October 23, 2012
Figure 1 Testing of wireless GTAW foot pedals revealed that even welders who worked exclusively in a small area liked the idea of having no cord on the floor. A cord often was hard to pull along as the welder changed positions. The... Read more... -
SMAW: The lowdown on the lingo
Article
July 25, 2012
From keyhole to downhill to arc blow, the lingo associated with SMAW is a common occurrence you may encounter in the process. When it comes to shielded metal arc welding (SMAW), following formal welding procedures is critical to... Read more... -
When hot, welding becomes not so hot
Article
February 28, 2012
Figure 1 Welding transmission poles and structures is a challenging job even in the most comfortable of environments. Combine the activity with very hot conditions, and the task becomes that much more difficult. Valmont Industries,... 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... -
More arc-on, less arc-off
Article
January 27, 2011
Figure 1 The welding booths at Impulse Mfg. Co. are designed for optimal efficiency, with parts staged in stackable, space-saving metal carts. Photo courtesy of Impulse Mfg. Co. Several years ago managers at Impulse Mfg. Co.... Read more... -
Specialty fabricator goes wireless with GTAW foot pedals
Article
October 4, 2010
Welders often are restricted by the length and cumbersome nature of cords, wires, and lead required to lay a weld. These elements restrict movement around weld cells, clutter the floor, and create impediments to safety and productivity.... Read more... -
Building a stronger welding program
Article
June 7, 2010
Old cylinder tops, valves, and scrap metal donated from local industry contribute to the Welding Rodeo's success. Bellingham Technical College (BTC) held its 9th annual Welding Rodeo May 21 - 22, 2010, on its campus in Bellingham,... Read more... -
Robotic advancements in welding tube, pipe
Article
June 4, 2010
Figure 1 Unlike sheet metal and plate, most of which are flat and require straight 2-D welds, tube and pipe have an endless variety of shapes, diameters, and joint configurations. Each application has a unique welding path and therefore... 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... -
Don't let your equipment leave you fuming
Article
April 27, 2010
New hexavalent chromium exposure limit regulations, set to take effect this year, aren’t the only reason your company might want to consider investing in a welding fume extractor. Welding fume extractors can help you attract highly... Read more... -
Pulsed GTAW for stainless steel
Article
April 1, 2010
Figure 1 Proper fit-up and good control of the welding parameters go hand-in-hand in producing successful fusion with minimal distortion. A poor fit-up requires more weld metal to fill the gaps. More metal means more heat, which leads to... Read more... -
No purge, no problem
Article
January 6, 2010
Figure 1 The Gateway Energy and Coke Co. in Granite City, Ill., is a dual-use facility. It uses coal to produce coke for use in manufacturing steel, and the exhaust from this process produces steam to generate electric power. The main steam... Read more... -
Induction system speeds pipe welding projects
Article
December 1, 2009
When it comes to pre- and postweld heat treatment, many fabricators see it as a choice between resistance heating with ceramic heating elements or flame heating with weed burners. However, they have another option: noncontact heating with an... Read more... -
One size does not fit all
Article
November 24, 2009
Figure 1 Push-button process selection potentially saves pipe fabrication shops $13,000 per year by reducing changeover time. Unless you're that exceptional standard-sized person, chances are that one-size-fits-all clothing... Read more... -
One size does not fit all
Article
November 24, 2009
Figure 1 Push-button process selection potentially saves pipe fabrication shops $13,000 per year by reducing changeover time. Unless you're that exceptional standard-sized person, chances are that one-size-fits-all clothing... Read more... -
Cutting cable clutter
Article
September 29, 2009
Ivan Newcomb, a journeyman pipe welder with UA Local 598, performs GTAW with an inverter at a work site about 10 feet below ground. "We just brought the inverter down and started welding right away. There was no pulling lead or need to change... 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... -
Stick welding: Tips for top performance
Article
August 1, 2009
For those who are new to it or perhaps who don't weld every day, stick welding—also known as shielded metal arc welding (SMAW)—is one of the more difficult processes to learn. Experienced welders who can pick up a stinger, pop an... 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... -
The GTAW top 10
Article
July 1, 2009
Figure 1 This GTAW is the result of poor gas coverage, which can be caused by a number of factors. Gas tungsten arc welding (GTAW) often is specified to meet strict aesthetic, structural, or code/standard requirements. The process... Read more... -
Field welding repair
Article
June 9, 2009
Engine-driven welding generators feature 5,500 to 20,000 watts of generator power, depending on the model, for running grinders (pictured), drills, and other tools needed for field repair. Broken equipment—whether it's a large... Read more... -
Riding the right wave in aluminum welding
Article
May 19, 2009
Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, often is thought of as the most difficult welding process to master. Fortunately for welders, several technological advances have occurred, forcing many to rethink their... Read more... -
Piping in productivity on heavy-gauge stainless steel
Article
April 1, 2009
Stainless Piping Systems Inc., Toronto, is no stranger to demanding applications. The company specializes in engineering, fabricating, and installing complete piping systems for industries such as industrial process, pharmaceutical, water... Read more... -
The pressure's on!
Article
April 1, 2009
The fictional Captain Nemo piloted his submarine Nautilus 20,000 leagues under the sea. But Nereus, a hybrid remotely operated vehicle (HROV), enables real scientists to explore the deepest areas of the ocean. For example, the Challenger Deep... Read more... -
Pulse welding eases exotic-metal fabrication
Article
December 14, 2008
Fundamentally, steelmaking electric arc furnaces transfer energy—lots of it. Used at mini-mills throughout the world, the furnaces' graphite electrodes melt metal scrap and burn out chemical impurities. And water-cooled pipes are central... Read more... -
Cut it out
Article
December 14, 2008
Perhaps the easiest way to perform artistic plasma cutting, or to cut identical pieces, is to use a CNC plasma cutting table and a computerized art file. While tables can be purchased for about $20,000, if you don't have one, all is not... Read more... -
Eagles, dragons: Stainless steel takes on many forms
Article
October 14, 2008
A few years ago Kevin Stone, a senior fabricator, decided to combine his years of welding experience with his innate artistic ability and began creating stainless steel sculptures on a large scale. While people make the pilgrimage to... 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... -
20,000 welds under the sea
Article
July 29, 2008
Globe-trotting to places like Rio and Curaçao sounds like an adventure out of a spy movie. It's actually just another day at work for the underwater welding pros at Miami Diver Inc., Miami. Miami Diver and its partners in the SubSea... Read more... -
Innovative workholding streamlines welding at Vermeer
Article
February 12, 2008
Lean manufacturing drove Vermeer to organize weld cells for maximum productivity. Whenever possible, the company places fixtures in the weld cell, within the operator's reach. A decade ago welders at heavy-equipment manufacturer Vermeer... Read more... -
GMAW 101: Setting the correct parameters
Article
February 12, 2008
Good gas metal arc weld. Photo courtesy of Miller Electric Unless you weld for a living, it can be difficult to know if your gas metal arc welding machine is set up for optimal performance. Do you find yourself asking questions such as: Am... 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... -
These aren't your grandparents' wheelchairs
Article
December 11, 2007
Although it's called "wheelchair rugby" or "quad rugby"—it's played by quadriplegic athletes in wheelchairs—neither term really captures the sport's speed or intensity as does its original name: murderball. Nor do the athletes fit... Read more... -
Fabricator finds new opportunities in energy sector
Article
July 10, 2007
Welding chrome-moly steel has strict requirements concerning the welding process, preheat temperatures, and postheat temperatures. The specifications provided by the engineers for the New Hope Power Partnership project required GTAW on the... Read more... -
Blasting the bottleneck blues
Article
May 8, 2007
For Farmer & Irwin Corp., a mechanical contractor based in Riviera Beach, Fla., increasing the productivity of its HVAC pipe fabrication shop was more than just a good idea, it was a necessity. Founded by R.E. "Bob" Farmer and R.R. "Dick"... Read more... -
Improving manual plasma cutting quality
Article
March 13, 2007
If you're maintaining the proper travel speed, the sparks will exit the workpiece at a 15- to 20-degree angle. Plasma cutting is easy to learn, and cutters are simple to use. In fact, it's so easy that many users go right to work as... Read more... -
From Pens to Plasma Cutters
Article
January 9, 2007
Miller Electric brought in a semitruck load of welding equipment for fabricators to try out. The Miller staff verified that their insurance premium was up-to-date, crossed their fingers, and allowed me to try manual plasma cutting and GTAW.... Read more... -
High Roller meets fast cutter
Article
December 12, 2006
About 900 feet above the Las Vegas Strip, Brian Day uses a plasma cutter to cut apart the Stratosphere's High Roller roller coaster. About 900 feet above the Strip, Brian Day pauses for a moment and looks down on the early morning Las... Read more... -
Structurally, it's a job shop
Article
December 12, 2006
Structural steel from Suburban Steel Co. is used to frame a Huntington Bank branch in Grove City, Ohio. Structural steel shops can be as inflexible as the giant beams they supply to commercial and residential contractors. Jobs are booked by... Read more... -
Aluminum pipe pioneer streamlines tube mill welding
Article
October 10, 2006
Hastings Irrigation Pipe Co., Hastings, Neb., blazed a trail in the late 1940s by manufacturing irrigation pipe out of a material that was not used commonly at that time: aluminum. Five decades later Hastings and that unusual material are... Read more... -
The need to feed aluminum
Article
March 7, 2006
Aluminum, especially thin-gauge, presents unique welding obstacles. Gas metal arc welding (GMAW) in particular presents challenges in wire feeding and selecting the right type of filler metal and equipment. However, several options can aid... 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... -
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... -
Considering change
Article
May 10, 2005
But every family has secrets, and blind trust in an old FCAW procedure can weaken your competitiveness, especially if your company is maintaining the same productivity level from years ago. It's possible to improve... 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... -
Delta repair welders aim high
Article
July 13, 2004
Pilots refer to flying experience as "seat time." For the 300-plus certified welders in Delta Air Lines' TechOps division, the term has a similar meaning. Certification is just the first step for them. Qualified GTAW welders here log... Read more... -
Selecting the right tungsten
Article
February 26, 2004
But this isn't as true anymore, as the welding industry has shifted toward using inverter-based AC GTAW machines that incorporate square wave technology. Selecting the right tungsten becomes an increasingly critical issue with inverter... Read more... -
Metal Art Takes on the Fireplace
Article
February 26, 2004
Figure 1 After tracing the fireplace screen pattern on 12-gauge mild steel plate, Jim Truett performed his intricate cuts with an air plasma cutter. Truett knows his way around a welding power source and its allied tools, consumables... 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... -
Using inverter technology
Article
July 24, 2003
Those familiar with inverters usually know they offer size, weight, and portability advantages. They also can improve reliability by overcoming primary power fluctuations, also known as dirty power. Question: Does the weight of the... Read more... -
Reviving the past
Article
May 15, 2003
When he looked at the outside of his building, Bellingham, Wash., YMCA Director Dave Harding realized he faced a challenge. The original Bellingham, Wash., YMCA building. The YMCA's main downtown facility was located in an early-1900s,... Read more... -
Heating P91 boiler pipe
Article
March 13, 2003
Insulating blankets are an integral part of induction heating equipment. After the pipe is heated to the proper temperature, the induction coil is removed and the pipe is welded. "Our turnaround time averages eight to 12 weeks, and... 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... -
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... -
Cut it out: How fabricators use plasma cutters every day
Article
August 29, 2002
Many fabricators use plasma arc cutting torches every day, either to replace or complement saws, cut-off wheels, snips, and oxyfuel rigs. Fabricators say the use of this equipment has grown because it can be used in a variety of... 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... -
Welding chromium-molybdenum steel pipe for power plants
Article
July 11, 2002
Figure 1 Postweld heat treatment requires controlling temperature in four phases to relieve the stress caused by welding. As a result of nationwide power emergencies and an abundance of natural gas, 300 to 400 new power plants are... Read more... -
Earthquake shakes joint design, building construction
Article
May 16, 2002
Here's a dual challenge for a construction company: Help prevent future earthquake damage by retrofitting existing buildings in Southern California, and use new construction codes that most of the industry never has seen before. Do this type... 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...
