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Results: 56

Article

June 8, 2004
Spraying it right For coil-fed applications, spray cabinets can be mounted to the feeder to accommodate passline changes. Most stampers understand the need for lubricants, but many apply as little as possible so they don't have to deal with the mess. Others take an opposite approach and flood the tool... Read more...

Article

February 26, 2004
Selecting the right tungsten 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 technology to maximize its benefits. In the past pure... Read more...

Article

January 29, 2004
Occupational injury and illness statistics Statistics also were reported for cases that resulted in days away from work, a job transfer, or restriction and are grouped in two categories: those requiring at least one day away from work, with or without job transfer or restricted activity, and those requiring job transfer or... Read more...

Article

January 29, 2004
Managing environmental risk in tube, pipe production   Editor's Note: This article is adapted from a presentation made at the TPJ Symposium, March 16-18, 2003, Scottsdale, Ariz. The U.S. Congress and the states have created a complex scheme of environmental rules and regulations with which tube and pipe producers must comply.... Read more...

Article

January 13, 2004
One system does not fit all Breathing is something that many of us take for granted. Most don't give it a second thought—you inhale, you exhale. That's about it. But recently, and not just in manufacturing, the trend has been for employers to install better ventilation systems and provide better air... Read more...

Article

December 11, 2003
Taking tubular aluminum scaffolding to new heights Photo courtesy of Fred R. Tannery Photography, Brooklyn, N.Y. Universal Builders Supply, a temporary-structures company with headquarters in Mount Vernon, N.Y., designs and constructs scaffolding, hoisting, and platforms—big ones. It was the company's proposal for a unique... Read more...

Article

November 6, 2003
Meeting ISO 14001 requirements First published in 1996, ISO 14001 specifies the actual requirements for an environmental management system. It applies to those environmental aspects an organization can control. Achieving ISO 14001 requires documented improvement. First, you must document your current environmental conditions... Read more...

Article

October 23, 2003
Take control of safety   Often invisible to the human eyes, airborne contaminants can have serious consequences for your health. Be familiar with the potential hazards and the effects they can have on your respiratory system. The Occupational Safety and Health Administration (OSHA) standard 1910.134... Read more...

Article

October 9, 2003
Combating plate corrosion According to a recent study sponsored by the U.S. Federal Highway Administration (FHWA)1, with support from NACE International—The Corrosion Society, corrosion-related direct costs such as prevention methods and infrastructure repair and replacement make up 3.1 percent of the gross... Read more...

Article

September 25, 2003
Getting a handle on work-related hand injuries Of the 3.6 million work-related injuries treated annually in emergency rooms across the U.S., hands and fingers are the most commonly treated body parts, according to the U.S. Centers for Disease Control and Prevention. More than 90 percent of all acute injuries in the workplace are... Read more...

Article

August 14, 2003
Keep it clean A variety of technologies for treatment of industrial waste fluids produced by metalworking processes are available. Some of these technologies can treat waste from complex waste streams, even commingled, and allow you to reuse the water in your forming processes. Waste Treatment Options... Read more...

Article

July 24, 2003
Advancements in waterjet technology Stream Lag Caused Taper, Corner Problems Budd said he courted the gear processing market, but prospective customers wanted parts with a perpendicular edge, which he was not able to achieve with the 2-D abrasive waterjet equipment he was using. In 2-D abrasive waterjet cutting, the... Read more...

Article

June 26, 2003
Phases, structures, and the influences of temperature But phase changes can take place in many metals while still in the solid state. These phase changes are directly related to temperature and take place in the metal's crystalline structure. And while temperature is what controls these transformations, stress, cooling rate, and alloy or chemical... Read more...

Article

June 26, 2003
Selecting a table for abrasive jet machining Editor's Note: This article is the third in a series intended to help a prospective user evaluate abrasive jet machinery. The first article, Buying an abrasive jet machine , compared the abrasive jet process with other cutting processes. The second article, Software for abrasive waterjet... Read more...

Article

June 26, 2003
Making hands-free straight, saddle, and miter cuts Since its inception in 1969, the company had used traditional, manual processes. Pipes were moved into and out of the work area by forklift, and pipe cutting was done with either a hand-powered mechanized torch or a hand-held torch. For straight end cuts, an operator attached a... Read more...

Article

June 12, 2003
Al GMAW: CC or CV? 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? Can I use the more common CV power supplies or... Read more...

Article

June 12, 2003
Understanding weld discontinuities A welder's primary concern in any kind of work is ensuring his weld is sound. For this reason, it's important for an inspector examining the weld to be able to spot a variety of weld discontinuities, including: Porosity. Incomplete fusion. Incomplete joint penetration. Unacceptable... Read more...

Article

May 29, 2003
Robots and dials and knobs—oh my! It has been said that necessity is the mother of invention. You be the judge. In the late 1950s, the U.S. Navy wanted to find a way to join heavy aluminum structural sections used to fabricate motor torpedo boat hulls. Gas tungsten arc welding (GTAW) offered suitable process... Read more...

Article

May 29, 2003
Predicting the service life of galvanized steel Zinc, which has been used to hot-dip-galvanize steel for 250 years, provides 50 to 75 years of corrosion protection in many environments. Empirical data collected about hot-dip galvanized (HDG) steel field performance from 1940 to 1980—in environments ranging from industrial to... Read more...

Article

May 29, 2003
Batter up! Turning an aluminum tube into a baseball bat Although wooden bats still are the only type used in professional baseball, aluminum bats are used extensively in nonprofessional baseball and softball leagues. In fact, nearly 95 percent of all baseball bats used in the U.S. are made of aluminum. Hillerich & Bradsby Co. (H&B),... Read more...

Article

May 29, 2003
Art From the Forge It's been happening gradually over the past 25 years, but in the past four or five years, art from the forge is finding outlets in fine art and sculpture galleries, as public art and even jewelry. These motifs, techniques, designs, and objects are heading ironwork in new directions. Much of it... Read more...

Article

May 29, 2003
Defibrillators—Should you have one in your workplace? Photo courtesy of American Heart Science . In December 2001 the Occupational Safety and Health Administration (OSHA) released a statement encouraging employers to consider making automated external defibrillators (AEDs) available in their workplaces. This announcement followed the... Read more...

Article

May 15, 2003
Solving the mysteries of the fin pass—Part 2 First, some ground rules (assumptions) for the arrangement before we discuss some possible reasons for poor-quality seam welding and their solutions: 1. You are working with a new set of rolls and spacers. We assume that the rolls are manufactured correctly. This eliminates from the equation... Read more...

Article

May 15, 2003
Sick at Work? For some workers, various symptoms of illness appear when they enter the workplace and disappear when they leave. These workers suffer from sick building syndrome (SBS). According to the U.S. Environmental Protection Agency (EPA), SBS is used to describe situations in which building... Read more...

Article

April 10, 2003
Mixed Metals Reactions Why, you may ask, would anyone want to start an uncontrolled chemical reaction that is really hard to stop? Well, our shop did not want to, but we did anyway, and I hope you learn from my lesson. Actually, they are lessons (plural) because we repeated the disaster twice, although with some... Read more...

Article

November 17, 2002
Secrets of Using GTAW for Tools and Dies Tool and die welding can be a very lucrative service for a fab shop to offer. However, tool and die welders are a rare breed because of lack of knowledge about the process and the extra expense for a shop. Gas tungsten arc welding (GTAW) frequently is used for tool and die welding applications... Read more...

Article

July 26, 2002
Repair Brazing: Fixing Faulty Jobs and worn-out components Brazing is a versatile process used in many industries to join materials permanently. Repair brazing is an essential part of the industry and usually is done for one of two reasons—to braze repair parts in-house before they are released to customers and to perform repairs on brazed... Read more...

Article

July 12, 2002
It happens 'under the hood' Object Rick Walsh doesn't have a degree in landscape architecture, but he builds water gardens. He doesn't have a degree in art, but he sculpts metal. He has no formal training in welding, but welds all his sculptures. And for years people have been paying him a lot of money to create his... Read more...

Article

November 15, 2001
Gun Control: GTAW torch design innovations enhance productivity, quality Gas tungsten arc welding was developed during World War II to join hard-to-weld alloys such as zirconium, titanium, and aluminum. Later it proved to be equally successful on carbon, alloys, stainless steel, and other ferrous and nonferrous metals. Today GTAW is used heavily in the... Read more...

Article

November 15, 2001
Using hydroforming aluminum components versus steel stampings As the name implies, hydroforming is a metal forming process that uses water as a forming medium. In the case of tube hydroforming, a tubular workpiece is placed between two mating die halves. The tube is sealed, normally by metal mandrels inserted under pressure in each end of the tube. Water... Read more...

Article

October 11, 2001
Remote GTAW of spent fuel canisters: How this process reduces operator exposure to radiation Among many tasks that Nuclear Utilities perform is to ensure that radiation workers are exposed to the lowest possible amount of radiation. The industry has to follow strict exposure limits, and all nuclear energy workers must ensure the radiation exposure is as low as reasonably achievable... Read more...

Article

October 11, 2001
Staying safe during HF welding: A common sense approach to personnel protection In an era of corporate downsizing and intense competition, companies are under mounting pressure to keep operating costs to a minimum while improving productivity. Every program is being scrutinized to justify its continuation in this tough economic climate. However, companies should not... Read more...

Article

October 11, 2001
Interaction of chemicals used in forming and fabricating Lubricants, coolants, corrosion inhibitors, cleaners, coatings, fluxes, and other chemicals all are used-and thus intermixed-in metal manufacturing, forming, fabrication, welding, and finishing. As a result, as manufacturers become more conscious of quality, safety, productivity, and disposal... Read more...

Article

October 11, 2001
Installing and maintaining coil cradles and reels All stamping and forming operations outside of the powder or forging industries begin with coiled steel. In many fabricators' plants, the decoiler, payoff reel, recoiler, tensioner, or other coil handling equipment require constant maintenance. Installation The nature of the... Read more...

Article

September 17, 2001
Making seamless tubing with a floating mandrel mill Every six seconds, a single, 32-foot length of oil country tubular goods (OCTG) production tubing used in the exploration and production of oil and/or gas is produced. More than 20,000 miles of tubular product a year can be produced using the floating mandrel mill seamless tubular production... Read more...

Article

September 13, 2001
Selecting the right materials for roll forming—Part 2 Alloyed Steel In addition to carbon, large varieties of metallic and nonmetallic elements are used to achieve the desired mechanical properties and corrosion resistance. The most frequently used alloying elements are manganese, cobalt, chromium, copper, molybdenum, vanadium, nickel, zirconium,... Read more...

Article

September 4, 2001
Exploring complementary cutting methods Diversification is the linchpin of running a successful business. The key to producing quality work and investing in equipment wisely is knowing which cutting method—laser, plasma, electrical discharge machining, waterjet, or another—to use for a particular application. While... Read more...

Article

August 23, 2001
Stamp of Approval: Full-court press safety: How to maintain an effective safety program end to end When pressroom safety is discussed, the main focus often is the punch press and its peripheral equipment. However, comprehensive programs encompass a much broader spectrum of topics. Any helpful discussion of pressroom safety should include at least four major elements: People Equipment... Read more...

Article

August 16, 2001
Do your tubes seam good enough? Using eddy current testing to make sure To use this method, a manufacturer must have, as a minimum, eddy current test electronics, test coils and cabling, and some form of output device such as a strip chart recorder, paint marker, or alarm. More advanced systems include material handling and provide sophisticated flaw evaluation,... Read more...

Article

August 16, 2001
Tips on Lean Manufacturing: Mastering the stop 'n' go of your shop's work flow Kaizen—or continuous improvement—is based on the concept that there is always an opportunity to modify, enhance, or improve any process. For example, Henry Ford's model worked well for decades, but then representatives of Toyota Motor Corp. showed the world that improvement was... Read more...

Article

August 16, 2001
The Brakes: Press Brakes and You -- Preventing common mistakes on press brakes Press brakes—they're wonderful machines that, unfortunately, present many opportunities to make mistakes. The good news is that many mistakes are so common that a nice file of prevention tactics has stacked up against them. The following miscues and mishaps are commonplace—and... Read more...

Article

July 26, 2001
What to know before selecting a manual plasma cutter: Understanding size, power, components, cost The first plasma arc cutting (PAC) systems, developed in the '60s, were 1,000-amp monsters designed to blast through 6-inch stainless steel. Their mechanized torches were moved by X-Y cutting machines and powered by DC units the size of refrigerators. Surprisingly, the PAC industry... Read more...

Article

July 12, 2001
Not your father's abrasive jet Figure 1 Object Fifteen or 20 years ago abrasive jet was the technology of last resort for severing difficult materials that could be cut no other way. These units were crude, noisy, and dirty. A nozzle was hung on an X-Y burning table and the resulting tolerances and surface finish were... Read more...

Article

July 12, 2001
Thermal spray safety and OSHA compliance Object Thermal spray equipment normally is operated in special enclosures designed to reduce noise levels, extract fumes, and provide direct viewing of the spray nozzle when it's used in high production environments. Occasionally R&D projects, large parts, low production runs, or complex... Read more...

Article

July 12, 2001
Turning up the power Industry trends indicate that metal fabricators increasingly are selecting higher-power lasers for cutting applications. Two years ago, the most common power levels ranged between 1,500 and 2,000 watts. However, a statistical survey conducted by the AMT Laser System Product Group indicates a... Read more...

Article

June 18, 2001
The Brakes- Press Brakes and You -- How to get the most out of your press brake The press brake is perhaps the most valuable machine in the average fabricating shop. If the press brake is hard to set up and/or produces inaccurate parts, you are losing money every time you use the machine--excessive setup time, time wasted making bad parts, and scrap parts all cost you a lot... Read more...

Article

June 13, 2001
Rising expectations spark new approach to draw die development: Reconciling demands for increased quality at lower costs During the past five years, the process of draw die development has undergone significant changes as a result of technological improvements and the demand for higher-quality products. Figure 1: The eight steps in the advanced draw development process are designed to identify and address... Read more...

Article

May 30, 2001
Abrasive control factors for mass finishing systems Figure 1: Literally hundreds of media compositions, sizes, and shapes are available. With the advent of the Clean Air Act in the early 1970s, a new playing field for the coating industry began evolving. Simply providing better service and possibly better economics with the... Read more...

Article

May 30, 2001
The evolution of coatings with low levels of volatile organic compounds: Where the industry stands in its quest for zero VOC With the advent of the Clean Air Act in the early 1970s, a new playing field for the coating industry began evolving. Simply providing better service and possibly better economics with the established technology no longer could be the basis for long-term growth, but exciting new possibilities... Read more...

Article

May 15, 2001
Mill coolant system design Coolants are used to wash away oils, oxides, slivers, and dirt generated during the forming, welding, and sizing of tubes and roll-formed profiles. These coolants are a mixture of water and refined chemicals that help cleanse the process, protect part finish, extend tool life, and inhibit rust... Read more...

Article

May 15, 2001
Appliance industry takes a shine to powder blank technology   Among European, Pacific Rim, and U.S. appliance makers and other manufacturers with large-scale, appliance-grade finishing requirements, the use of powder blank line coating systems has grown steadily during the past 10 years. A powder blank coating line supplies coated blanks... Read more...

Article

February 19, 2001
Maintaining and troubleshooting HF welders: A common-sense approach for vacuum tube and solid-state machines Since the 1960s, the workhorse of the tube and pipe industry has been the high frequency (HF) vacuum tube welder. Recently, an increasing number of producers have been installing the HF solid-state welder, in part because of its efficiency, compact design, and high power factor. Many vacuum... Read more...

Article

February 19, 2001
Pressure-sequence and high-pressure hydroforming: Knowing the processes can mean boosting profits Closed-section structures have long been important in vehicle design. Typically, these have been assembled with several stampings, because no practical way existed to form tubes into complex shapes at required quality levels. Holes were more costly than in stampings, and some types... Read more...

Article

February 19, 2001
Handling metal stamping wastes: Protecting the environment - - and your business Possessing an in-depth knowledge of the latest metal stamping techniques, methods, tooling, and machinery is obviously a desirable trait for any professional in the metal manufacturing and fabricating industry. Unfortunately, the same value is not always placed on being knowledgeable in... Read more...

Article

February 19, 2001
Joining aluminum with GTAW: Advice for the novice Aluminum: beautiful, lightweight, strong, versatile—and a real challenge to weld, especially for beginners. This article describes some of the new gas tungsten arc welding (GTAW) equipment available and its benefits, accessories required, points to consider before welding, and the... Read more...

Article

February 19, 2001
Advantages of plasma welding: Often-overlooked PAW offers speed and affordability Object Plasma arc welding (PAW) often is overlooked when a fusion welding process must be selected for high-integrity applications such as those found in the medical, electronics, aerospace, and automotive industries. This process has been overlooked because it is more complex and requires... Read more...

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