Understanding Duty Cycle for Welding Machines

One of the specs we need to know about a particular welding machine is its duty cycle.  The duty cycle gives you an idea of how hard and how long you can run a welding machine before it overheats and shuts down.  Unfortunately at times we have issues with machines exceeding the duty cycle when it shouldn’t, […]

Why Are Fillet Break Tests Done for Welder Qualifications

When qualifying a welding procedure specification (WPS) for  fillet welds per Clause 4 of AWS D1.1 Structural Welding Code you must only perform a single test.  You must do macroetches in three locations as shown below. It is assumed that if we can show root fusion at these three locations that our welding procedure is […]

How to Calculate Deposition Rate for Solid Wires

A common question that is asked when manufacturers are trying to determine costs associated with welding is: How many pounds of wire can I deposit per hour? Or, how many pounds of wire can I deposit at a specific amperage or wire feed speed?   There are charts to help you determine this, but it’s always […]

The Best Piece of Equipment to Reduce Welding Costs

Many fabricators spend thousands of dollars in new welding equipment every year.  They look for the latest and greatest technology that will allow them to reduce manufacturing costs.  We have seen some of our customers justify the purchase of robots and other types of advanced welding equipment relatively easily.  Some pieces of equipment pay for […]

Can Pulse Really Solve All Your Welding Problems?

Competition amongst manufacturers of welding machines is a wonderful thing.  Companies like Miller, Fronius, OTC, Lincoln Electric, and many others are continually improving their equipment, making it more user-friendly and at a lower cost.  We as users benefit from this.  However, this has brought about a significant problem, a huge epidemic. And that is the […]

9 Steps to Develop a Repair Welding Procedure

Some repairs, whether it is repairing a failed weldment or repairing a crack in a casting, may easily be done by simply grinding out the crack and applying more weld.  Other repairs, however; are more complicated.  Or at least they should be. Just last week a customer contacted us asking for help in developing a […]

What Filler Metal Should be Used to Weld Carbon Steel to Stainless Steel

And can you use stainless wire to weld carbon steel to carbon steel

It is not uncommon to find fabricating shops that are welding a variety of metals including carbon steel, stainless steel, aluminum and nickel alloys.  In many cases some of these materials need to be welded to other types.  Once very common situation, especially in automotive applications is welding carbon steel to stainless. One of the […]

9 Common Problems with Welding Procedures

They can do more than simply fail an audit

The use of welding procedures specifications (WPS) is the foundation of a good welding quality control management system. It has a huge impact on quality as well as productivity.  Despite this, many fabricators are still running their facilities without WPSs.  And many who are, have significant issues which prevent this powerful document from maintaining quality […]

Welding Cast Iron

Cast iron is not impossible to weld, although many that attempt to do so end up with cracked welds. The reason welding cast iron is a big challenge is that it contains up to 4% carbon.  This is an insane amount, considering that any material with a carbon content above 0.30%  is already considered “high […]

The Advantage of Using Undermatching Filler Metals on High Strength Steels

High strength steels are becoming more and more popular in steel construction.  Higher strength means we can reduce the thickness of the base material and thus reduce weight.  This is very important not just in vehicles but in static structures as well.   However, higher strength steels usually bring about a few issues that if not […]