Content tagged with "gmaw"
Results: 76
Article
April 1, 2010
Welding thin with GMAW
Figure 1
In experienced hands, the gas tungsten arc welding (GTAW) torch can produce solid, almost cosmetically perfect joints in extremely thin metal. Today, however, GTAW isn't the only option, even for thin, heat-sensitive material. Gas metal arc welding (GMAW) process... Read more...
Article
March 1, 2010
A GMAW consumables check list
Figure 1 All contact tips may look the same at first glance, but it's important to make sure you're using a tip with an opening that is not too tight or too loose for the wire being fed through it. Welding consumables, as the name indicates, are parts that get consumed—either worn... Read more...
Article
March 1, 2010
Beyond low-carbon steel
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 bring in new work, and even pursue untapped... Read more...
Spanish
February 9, 2010
Article
January 14, 2010
Love your gloves
To get the best results from your welding gloves, it is imperative to match your process with the appropriate materials.
For many welders, pulling on a pair of welding gloves is second nature. What may not be second nature, however, is choosing the right glove to fit your needs of... Read more...
Article
January 12, 2010
Keeping sight of the little things
Choosing the right robotic GMAW gun, consumables, and wire can be just as important to productivity and weld quality as the power source, tooling, and robotic arm. Robotic gas metal arc welding (GMAW) can provide companies with significant gains in productivity and excellent return on... Read more...
Article
November 24, 2009
One size does not fit all
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 requires compromises. While tight gloves pinch, and a... Read more...
Article
November 24, 2009
One size does not fit all
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 requires compromises. While tight gloves pinch, and a... Read more...
Article
November 6, 2009
Welders to the rescue
In emergency situations such as fires, health crises, or automobile accidents, we depend on firefighters and rescue personnel to respond quickly and provide assistance. In turn, rescue personnel depend on their equipment to function properly in order to provide assistance to those in need.... Read more...
Article
September 6, 2009
Robotic GTAW or GMAW: No longer a clear-cut choice
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: They've sometimes steered people away from it.
"I've... Read more...
Article
September 1, 2009
Preparing for GMAW, back to basics: All about setup
Of all the welding processes, gas metal arc welding is the easiest to learn. However, setting up a GMAW system isn't quite so straightforward. The wire feed process is all about setup, really, and improper setup can lead to some major problems.
If machine settings are... Read more...
Spanish
August 17, 2009
Spanish
July 23, 2009
Automatizando lo pequeño
Figura 1
Dados los parámetros correctos, los robots soldadores pueden aumentar la eficiencia, incluso con las producciones más pequeñas de partes.
Recientemente le cortaron el pelo a mi hijo. Es un niño, por lo que el peluquero no tiene que cortarle demasiado cabello, pero a sus 5... Read more...
Spanish
July 7, 2009
Pistolas GMAW: más que una mercancía
No piense que una pistola GMAW es lo mismo que otras. Escoger la pistola adecuada para el trabajo puede conducir a mejores soldaduras.
Muchos soldadores piensan con frecuencia en una pistola de soldadura por arco metálico (GMAW, por sus siglas en inglés) como un producto no especializado... Read more...
Article
April 14, 2009
Welding with vision
If you had asked anyone in manufacturing five years ago, "What is your opinion of using a vision system in the welding environment?," you may have heard answers like "not practical," "too sensitive," "too costly," or "too much maintenance." But today's vision systems, with cameras placed... Read more...
Article
April 1, 2009
Piping in productivity on heavy-gauge stainless steel
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 treatment, food and beverage, automotive,... Read more...
Article
March 24, 2009
Smooth wire feeding, smooth welding
Figure 1
Welders often take inconvenience for granted. If a wire feeds inconsistently, or if setup takes forever and a day, so be it. It's the way it's always been, so why question it? Nevertheless, questioning everything is a key tenet of lean manufacturing, and it need not be... Read more...
Article
March 24, 2009
Smooth moves with GMAW
To steady your hand, brace your elbow or upper arm against a tabletop or other secure object.
Welders of the world have a secret: Gas metal arc welding really isn't that difficult, if you have the correct equipment setup, if you can see the wire feeding into the weld, if you move... Read more...
Article
March 10, 2009
You can plasma cut it, but can you weld it?
A lot happens in a plasma arc from its generation at the electrode surface to the workpiece. Among numerous other factors, the plasma forming gas and its surrounding shield material, be it gas or liquid, play a major role in the final cut quality.
A high-quality cut is characterized by a low... Read more...
Article
March 10, 2009
It takes two, baby
Hybrid laser-arc welding (HLAW) is not a new concept, but it has gained in popularity recently. Faster travel speeds, less heat input and distortion, and higher tolerances make HLAW a great alternative to laser welding or arc welding processes alone. The most common combination is laser and... Read more...
Article
January 13, 2009
Straightening out GMAW gun feedability
Whether you weld every day as part of your profession or occasionally as a hobby, you are probably always looking for ways to improve the structural integrity and cosmetic look of your welds. Numerous machines on the market today can help with one or both of those issues, but machines... Read more...
Article
December 14, 2008
Pulse welding eases exotic-metal fabrication
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 to the design. The better they transfer heat and... Read more...
Article
December 14, 2008
Understanding transfer modes for GMAW
The gas metal arc welding (GMAW) process uses four basic modes to transfer metal from the electrode to the workpiece. Each mode of transfer depends on the welding process, the welding power supply, and the consumable, and each has its own distinct characteristics and applications.
Several... Read more...
Article
November 25, 2008
Do your welds pass muster?
When competing in a global economy, it pays to weld it right the first time.
Rework and scrap add significant cost to a manufacturer's balance sheet. Missed delivery dates increase customer dissatisfaction and defection. Poor weld quality may even cause a customer to carry excessive... Read more...
Article
November 25, 2008
Truckin' along
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 truck bodies, hoists, and truck and trailer... Read more...
Article
October 28, 2008
The root causes of weld defects
Weld defects happen for a host of reasons. Air may creep into the weldment to cause porosity. The wrong amount of heat can cause cracking. Bad welding technique can cause undercuts or incomplete penetrations of one kind or another. Various factors contribute to weld problems, but many lead... Read more...
Article
October 14, 2008
Don't be marginalized
Robotic welding systems introduce speed, accuracy, and repeatability into the fabrication process. The repeatability of these systems can increase productivity and reduce welding production costs, thereby maximizing the return on the investment in automation. When compared to semiautomatic... Read more...
Article
September 26, 2008
A 'Case' for agility
Figure 1
Three identical robotic welding systems stand in a row, each system controlled by one operator. All Case New Holland robot operators are certified welders.
Case New Holland (CNH), the global agricultural and construction equipment giant, is bursting at the seams. Its... Read more...
Article
September 16, 2008
Automating the Small
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 some time to get him seated and adjusted to a... Read more...
Article
June 17, 2008
Troubleshooting welding conductivity
Tight connections between the cables, feeder, power source, gun components, and the workpiece are essential to delivering a consistent current to the welding arc. Mechanical faults anywhere along the circuit can lead to resistance and poor welding performance. Electrical conductivity is at... Read more...
Article
June 17, 2008
Auto weld that ends well
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 manufacturing engineer, asked themselves a question... Read more...
Article
June 17, 2008
Tips for troubleshooting GMAW consumables
Making a high-quality gas metal arc weld is no easy task. But making a high-quality weld when your gun and consumables aren't functioning properly is just about impossible. Porosity, excessive spatter, undercut, and burnback are just a few of the problems that can occur when something's not... Read more...
Article
April 15, 2008
Modified GMAW for root passes
A new, modified short-circuit transfer technology can help stainless steel pipe fabricators increase productivity to meet the growing demand for energy-related goods.
For stainless steel pipe fabricators, the good news is that the oil refining and petrochemical sector is experiencing... Read more...
Article
March 11, 2008
The facts on welding titanium
Many engineers and fabricators believe that titanium is a mysterious and difficult metal to weld—a fact that contributes to its exclusivity and relegates it to the high-end performance requirements of the aerospace market, the distance-driving desires of golfers, and the need-for-speed... Read more...
Article
March 11, 2008
Virtually welding
A virtual reality simulation of gas metal arc welding a fillet weld. A recent study led to an odd conclusion: Playing video games may produce better surgeons. Really, it's true, at least according to researchers at the Banner Health Center in Phoenix. They had surgical residents play... Read more...
Article
March 11, 2008
Automation in tube and pipe welding
Robotic welding of tube and pipe means more control over a task that can be grueling for welders if done manually. Encompassing applications ranging from exhaust systems and fenders to furniture and fencing, tube and pipe welding is a complicated task. That's why robots make so much sense.... Read more...
Article
February 12, 2008
GMAW 101: Setting the correct parameters
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 I using the proper voltage? Do I have too much... Read more...
Article
January 15, 2008
Keeping consumables from consuming welding profits
The employees of Tico Manufacturing Inc., Ridgeland, S.C., know a few things about the importance of durability. The company builds terminal trucks and trailers that load and unload shipping cargo weighing up to 300,000 pounds.
"Our trucks are not made to be cosmetically beautiful pieces... Read more...
Article
September 11, 2007
The tipping point
Contact tip recess isn't usually the first thing welders think about when they contemplate getting the best performance from their gas metal arc welding (GMAW) equipment. Using the wrong contact tip recess, however, can make a quality weld difficult to produce with even the best equipment and... Read more...
Article
August 22, 2007
Great welds need the right gas
Often overlooked as a factor in weld quality, shielding gas can play a significant role in improving, or impeding, welding performance.
If you're reading this, you probably already know that shielding gas plays a critical role in achieving a strong, visually appealing gas metal arc... Read more...
Article
July 10, 2007
Fabricator finds new opportunities in energy sector
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 first three passes of the pipe. Founded in 1988 in... Read more...
Article
May 8, 2007
Blasting the bottleneck blues
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" Irwin in 1956, the company is committed to meeting... Read more...
Article
April 10, 2007
Pipe fabricator saves big time with big bends
A four-roll bender carries a higher price tag than most three-roll benders, but it might be the easiest to operate because the material fed into the machine is clamped during the squaring process and held during the entire rolling operation. Photo courtesy of Bertsch. Tom Mooney, the... Read more...
Article
January 9, 2007
7 effects of shielding gas
Although you probably know that shielding gas is essential in most welding procedure specifications, you may pay little attention when you're selecting it. A simple gas composition change can offer potential savings in seven key areas, particularly in gas metal arc welding (GMAW).... Read more...
Article
January 9, 2007
Moving to modular welding fixturing
Wrayco Industries Inc. specializes in fabricating fuel and hydraulic tanks for heavy equipment such as backhoes, excavators, large off-road trucks, and generator and pump sets. It also manufactures tanks for specialty over-the-road applications from 0.16- to 0.47- inch mild steel plate,... Read more...
Article
November 7, 2006
Drive fast, weld right
"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 drivers. One of the most critical components is welding,... Read more...
Article
November 7, 2006
New rule, new equipment
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 ceilings and air-conditioning equipment already in... Read more...
Article
November 7, 2006
Joining GMAW and GTAW
The American Welding Society has defined "hybrid welding" as the combination of two distinct welding energy sources within a single welding process.
Figure 1
A new hybrid welding approach combines a plasma arc and a GMAW arc into one process. These elements detail the process: (1)... Read more...
Article
November 7, 2006
Using job shop habits for a custom project
Like any good businessman, Ed Sauvola wants to take his company in a successful direction. That's why this instructor-artist-welder-machinist was interested in the challenge of designing custom welding fixtures for a manufacturer in his area. Sauvola (see introductory photo) has plenty of... Read more...
Article
October 10, 2006
Luminous aluminum makes light work
Hapco had to design and fabricate aluminum light posts to replicate the art deco, Empire State Building period look of cast-iron poles made 70 years ago as part of a Triborough Bridge renovation project. The paint color had to be custom-blended to resemble cast iron. Special mounting bases... Read more...
Article
September 12, 2006
Bridging the challenges
Made from API 5L grades X52 to X60 pipe, the Tempe Town Lake Bridge was fabricated in segments and assembled on-site. In an Arizona match-up between concrete and steel, metal edged out the competition. This contest started in July 2003 when a design team began discussing the Tempe... Read more...
Article
September 12, 2006
GMAW guns: More than a commodity
Many welders often think of a gas metal arc welding (GMAW) gun as a mass-produced, unspecialized product—a commodity—when purchasing a GMAW system. More costly components, such as the power source, wire feeder, and shielding gas, generally take precedence, and the gun often... Read more...
Article
September 12, 2006
Little Giant takes flight
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 percent. Hal Wing's family business started 32... Read more...
Article
July 11, 2006
Innovation rides the waves
U.S. Air Force security police use this response boat to conduct sea trials. Bellingham, Wash., has a long tradition of seafaring sailors and boat-builders. During the 1800s many full-rigged ships hauled lumber to places like California and Hawaii. During World War II wooden mine... Read more...
Article
July 11, 2006
Reaching peak performance, productivity
Robotic welding has helped Alpine Engineered Products improve productivity, weld consistency, and overall product quality; eliminate outsourcing; and cut lead-times for its line of truss fabrication tables. The company invested inrobotic welding equipment that performs 85... Read more...
Article
May 9, 2006
Metal fabricating in a new millennium
"What I wanted to do in Millennium Park is make something that would engage the Chicago skyline ... so that one will see the clouds kind of floating in, with those very tall buildings reflected in the work. And then, since it is in the form of a gate, the participant,... Read more...
Article
May 9, 2006
Hitting pay dirt -- in pipe
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 opportunity for welders and pipe fitters these days.... Read more...
Article
May 9, 2006
Optimizing flow through robotic welding workcells
Figure 1
One of the new CNH systems welds on a loader chassis. Veteran industrial robotic user Case New Holland (CNH), Fargo, N.D., recently installed three robotic welding systems. Each system consists of an inverted robot on a large, three-axis traveling column and two... Read more...
Article
April 11, 2006
Getting autobody welding down cold
Figure 1
Metalworkers perform finishing work on the weld seam of an A-pillar.
The bodywork for the Phaeton® and Bentley Continental GT® limousines is built at Volkswagen Sachsen's Mosel facility in Saxony, Germany. The purchasers of these models expect perfection... Read more...
Article
March 7, 2006
A new way to weld sheet metal
Figure 1 Nu-Way Industries Inc. turned to laser seam welding to fabricate this stainless steel microwave enclosure. The old way didn't work for Nu-Way Industries Inc., Des Plaines, Ill. The large custom sheet metal fabricator needed a new method of welding to replace the traditional... Read more...
Article
March 7, 2006
The need to feed aluminum
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 in effective aluminum welding. In its pure form,... Read more...
Article
February 7, 2006
Making your way as a job shop today
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 upgrading. With a small, $200, one-afternoon job,... Read more...
Article
January 10, 2006
Elements of success:
You may know that air and water are two of the four astrological elements, but you may not know just how much they can affect your welding performance.
Torches, cables, and cooling are three integral components in gas metal arc welding (GMAW) and gas tungsten arc welding... Read more...
Article
November 8, 2005
Using flat wire in GMAW
These shielding gas nozzles are standard for flat-wire applications. Companies that manufacture products requiring intensive welding are being forced to optimize their production processes and produce more efficient welding methods to remain competitive. They must use new technologies... Read more...
Article
November 8, 2005
Getting the needed fixtures
Sitting on top of a modular fixturing table, a rock wheel frame attachment for a skid steer is finish-welded. Variety is the spice of life for Woods Equipment Co. The Oregon, Ill.-based company is a manufacturer of attachments and implements for agricultural tractors, skid steers,... Read more...
Article
October 11, 2005
'Star Wars,' move over: Presenting ... the Job Shop Trilogy
Laser welding is the basis of hybrid laser-arc welding. First flat-sheet bed cutting expanded job shop capabilities. Then multiaxis processing came along. Today, even as the dark side squeezes hard on job shop profits, new opportunities for differentiation continue to arise. Enter... Read more...
Article
September 13, 2005
Resolving the challenges of welding coated steels
The increased use of coated (particularly galvanized) steels has resulted in an intensified search for solutions to the problems posed by joining these materials. High levels of spatter and welding fume, weld porosity, and poor bead shape are common. These problems lead to increased postweld... Read more...
Article
June 14, 2005
How to choose the consumables you use - Part I
Many factors influence gas metal arc welding (GMAW) consumable selection. Chief among the factors is productivity. Because 85 percent of the cost of making a weld is labor, you need to choose consumables based on how well they improve welder productivity and minimize downtime... Read more...
Article
April 11, 2005
MIG welding tips and resources
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 Society (AWS) Welder of the Year because of his... Read more...
Article
April 11, 2005
Incorporating beveling economically
It's first important to know why and how beveling is used, and the key is realizing that joint design is process-dependent. In other words, you can't use a certain joint configuration from a book for just any process. Changing your welding process will affect the impact beveling has on... Read more...
Article
January 11, 2005
More about MIG welding
Editor's Note: This article is a companion piece to Marty Rice's article MIG welding—The basics and then some .
My first time using MIG (also called gas metal arc welding, GMAW) in the field was working on four stainless steel hoppers (tanks) at an Owens Corning plant. X-rays of the... Read more...
Article
September 14, 2004
Caring for your contact tips
The contact tip is one of the smallest and relatively inexpensive components in a gas metal arc welding (GMAW) system, but it can cause catastrophic failure and production downtime, highly penalizing productivity. The basic function of the contact tip is to transfer welding current to the... Read more...
Article
February 26, 2004
Efficient shielding gas supply methods
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 which the gas can be supplied, and the volume of... Read more...
Article
August 28, 2003
Article
February 19, 2002
How to Improve Your Welds: Helpful hints for GMAW
Gas metal arc welding (GMAW) is a semiautomatic welding process that uses a wire electrode fed through a welding gun. This continuous wire feeding during welding frees up the welder and allows him or her to focus fully on the gun position so that the proper arc length is maintained. A typical... Read more...
Article
July 26, 2001
Choosing the right shielding gas and supply system for GMAW
Selecting a gas metal arc welding (GMAW) shielding gas and supply system demands a cost and capability analysis to determine the most economical, efficient solutions for your operation. The cost of the welding gas selected may be a small percentage of the overall process cost, but the... Read more...
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