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Aluminum filler metals: What you should know about selection, storage, operation, and equipment
Aluminum requires special attention during welding. Among the critical considerations for optimal aluminum welding is proper filler metal selection.
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The impact of impact toughness
Choosing a filler metal with the right mechanical and chemical properties for your application is critical. Correct properties not only ensure the proper weld strength, but may also help prevent costly complications. In applications that endure...
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What's up with helium for welding applications?
Helium has been hard to get for some, and certainly the consumable gas is more expensive for welders than it used to be. The bad news is that this may be the case for some time. The good news is that alternatives are under development to help...
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Handling, installing, and maintaining GMAW consumables
For GMAW consumables in particular, several pitfalls exist that can shorten their life span. Taking the time to learn tips for keeping them clean and lasting longer can positively affect productivity, quality, and the bottom line.
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Handling, installing, and maintaining GMAW consumables
For GMAW consumables in particular, several pitfalls exist that can shorten their life span. Taking the time to learn tips for keeping them clean and lasting longer can positively affect productivity, quality, and the bottom line.
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Advancements in FCAW
Flux-cored welding is growing in popularity, yet its dependence on high concentrations of CO2 has prevented fabrication shops that employ a bulk gas delivery system from using the process. Recently wires have been developed that utilize a higher...
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Welding heat treatable steels
Our shop won a contract that requires welding 4130 steel. I've been told this is a heat-treatable steel. Can you tell me which different welding procedures have to be used to weld this material?
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Demystifying metal-cored wires
Even though metal-cored wires have been gaining popularity in recent years, there seems to be some mystery and misconceptions surrounding this filler metal. To better understand these wires it helps to consider the technology behind them and the...
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Face to face with hardfacing
Selecting the appropriate hardfacing alloy can be an intimidating experience due to the variety of applications, service conditions, and base metals. Learning to ask the right questions will help you make the decision that best fits your application.
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Welding chrome-moly steel
Welding chrome-moly tube and pipe conventionally is done with shielded metal arc welding (SMAW) or submerged arc welding (SAW). Flux-cored arc welding (FCAW) has been tried, but the wires had some drawbacks that prevented widespread acceptance....
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Shielding gas consumption efficiency
This is the second part of a two-part series
on making shielding gas systems more efficient.
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Rethinking weld shielding gas selection
When it comes to selecting shielding gases for certain welding processes, welders need to challenge their old-school thinking.
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Examining the X-factor
The X-factor, also known as the Bruscato factor, is an important equation for anyone welding with chrome-moly steel. The equation will help you test your filler metals for levels of phosphorus, antimony, tin, and arsenic that could make a weldment...
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A GMAW consumables check list
This article looks at contact tips used in GMAW and discusses a few tips to help industry professionals and welding enthusiasts get their money is worth from MIG contact tips while still guaranteeing high quality workmanship.
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Consuming plasma consumables too quickly?
All plasma systems use consumables that have an expected life. In high-use environments the cost of consumables can become considerable over time. Familiarizing yourself with what causes premature consumable wear and how to prevent it can help...
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No cracking under pressure for pipeline contractor
Progressive Pipeline Inc., Meridian, Miss., found that a new low-hydrogen vertical electrode made a real difference in a pipeline project the company worked on in 2008.
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Understanding low-alloy steel
Alloys comprise 1 to 5 percent of a particular steels content and are added to provide the steel with a specific attribute. Knowing the type of low-alloy steel you have will help you to choose the right filler metal and achieve good weld quality.
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Know your TIG torch
Even though money is tight, saving it by purchasing less reputable GTAW torches or skimping on maintenance practices can cause more harm than good in the long run.
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Welding Update for Infrastructure: Selecting filler metals for seismic requirements
FEMA, AWS, and AISC have all released documentation andspecification guidance for structural steel construction projects.Determining which to follow, however, can be a source of confusionfor architects, contract engineers, welding engineers, and...
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Welding Update for Infrastruture:Heating up takes time
The good news about a worldwide recession is that steel prices are back down from their record highs of 2008. The Producer Price Index for hot-rolled bars, plates, and structural shapes, which includes a lot of bridge steel, dropped 7.5...
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Finding an ally alloy
Choosing the best filler metal for aluminum welding involves takinginto account the operating conditions of the finished weldedcomponent as well as six important variables that can affect theoperating condition.
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Sizing up seismic-friendly filler metals
I am confused about the various specifications for seismic applications. How can I know if I have the right filler metal for the job? Your confusion is understandable. The documents overseeing seismic applications are ongoing and constantly...
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The next generation of VOC-free vanishing lubricants
Sooner or later,your operation will have to be free of volatile organic compounds emissions. Using the latest lubricants can help. Lubricant suppliers have developed VOC-free lubricants that combine the best qualities of vanishing oils and...
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A shielding gas primer for GTAW
With so many blends of shielding gas available, it can be a difficult task to determine which gas or gas blend best suits a particular GTAW application. To simplify that task, you must first understand the distinct properties that each gas or gas...
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Understanding transfer modes for GMAW
The mode of transfer you choose when using gas metal arc welding depends on your requirements, application, and equipment. This also affects the type of filler metal you use.
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Do your welds pass muster?
For a job shop or manufacturer, maintaining weld quality begins with consistent shielding gas in the gas metal arc welding (GMAW) process. Consistently delivering the correct blend ensures proper arc characteristics and weld quality. Mixing...
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Filler metal product approvals
Filler metal product approval codes can seem like a foreign language. One thing is certain, and that is each agency that establishes product approvals, such as AWS or ASME, does so to ensure filler metals meet the requirements for which they are...
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Helium: In short supply
Shops that perform stainless steel, aluminum, or laser welding are feeling effects of the current helium shortage. Looking into gas blends with lower percentages of helium or alternative gases, and ensuring that day-to-day welding practices are...
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Selecting and preparing tungsten electrodes
Selecting and preparing a tungsten electrode for welding involves choosing the correct electrode diameter, and prepping the electrode with the appropriate process and equipment. Successfully performing all three will allow for a consistent and...
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Keeping consumables from consuming welding profits
Like every manufacturer these days, truck and trailer manufacturer Tico Manufacturing Inc. can't afford to waste any time on non-value-added activities. It recently switched its welders to Centerfire™ nonthreaded contact tips manufactured by...
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New lube gives the slip to stamper's slips, trips, and falls
KI USA, a division of KI Japan, stamps and produces sub-assembly parts for Toyota, Honda, Nissan, and other "transplant" automotive OEMs. The stamper wanted to improve plant safety by reducing incidents of slips and falls. Petroleum-based stamping...
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Programmable lubricant application accelerates stamper's die changes
Red Rock Stamping, Chandler, AZ, airbag and seatbelt components manufacturer, looked for ways to improve its die change processes to handle the anticipated business volume increases. A lot of cleanup had been required around the machines as a...
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Choosing shielding gases for arc welding
Proper selection of the shielding gas for gas metal arc welding (GMAW), flux-cored arc welding (FCAW), and gas tungsten arc welding (GTAW) processes can dramatically improve speed, quality, and deposition rate of a given weldment.
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The tipping point
Incorrect contact tip recess can cause excessive spatter, burn-through and warping, insufficient penetration, and porosity. Welders who become familiar with correct tip recess can avoid these problems as well as unnecessary equipment upgrades yet...
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Flood-weld forging dies and large castings
COR-MET has been manufacturing flux cored wire and electrodes since 1972, specializing in high deposition alloys for the repair of Forging Dies and Large Foundry Castings. The Flood Welding Procedure will deposit up to 60 lbs per hour of weld...
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Beyond Commodity
Before making a process change to metal-cored wires, it is important to establish a baseline to measure the potential for improvement, know the wire's capabilities, and be able to justify such a change.
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What's all the 'flux' about?
Becoming knowledgeable about the different types of flux-cored stainless steel electrodes, what their capabilities are, how they are classified, and how to handle and maintain them safely can offer welders many benefits.
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Dam the purge gas and full speed ahead
Shielding gas is an often overlooked area of savings in tube and pipe welding. Creating a purge dam in one of several different ways can help you isolate the weld area and minimize the amount of gas and time needed to purge the weld zone properly.
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Cracking the case
Before welding abrasion-resistant plate, it's important to take certain precautions and choose the most appropriate filler metal for your application and weld metal.
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Examining the finer points of 6010, 6011, and 7018
Knowing which rods tend to do what in the field can save you time and make for better results when the job is through.
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The need to feed aluminum
While using aluminum can present challenges in any welding application, knowing the right questions to ask beforehand will help aid success. Issues include knowing what aluminum filler metal to use, how to store it, and what options are...
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Who you gonna call?
Shopping around for a welding gases distributor involves several key issues critical to a successful long-term business-distributor relationship.
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Using flat wire in GMAW
In manufacturing, new welding processes are being examined and tested while existing ones are being optimized. Specifically, conventional GMAW is evolving into a new process aimed toward helping fabricators and manufacturers realize increased...
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How to choose the consumables you use - Part II
Several small but crucial components—back caps, collets and collet bodies, gas lenses, and nozzles—are key components in enhancing GTAW productivity. These components are available in a variety of styles and sizes. Optimizing these...
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How to choose the consumables you use - Part I
Editor's Note: This article, which covers consumables for gas metal arc welding, is the first installment of a two-part article. Part II discusses gas tungsten arc welding consumables.
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Simplifying shielding gas selection
Have you ever asked yourself any of the following questions:
Why is welding affected by the shielding gases used?
Why are so many blends available for carbon steel?
Why can I use some gases for some materials and not...
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Site-based telemetry systems streamline gas supply
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,...
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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...
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Getting your assets in order
A new 4-kilowatt laser just hit the floor. The technician will arrive on Monday to install it. It's your responsibility to make sure the gases arrive. The preinstallation manual was faxed to your local gas supplier, and all is well. Not...
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Selecting a shielding gas for joining stainless steel
The use of stainless steel has grown significantly over the past decade in North America. As its use has grown, so has the number of different consumables required to join it. Because stainless steels are used in applications that are...
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