Importance of Macro Etch Testing of Welds

Macro etch tests are commonly done as part of qualification tests for welders and welding procedures. This test is relatively easy to do and does not require complex or expensive equipment.  However, very few fabricators ever perform this test. A macro etch test can serve as verification that a change on how something is welded […]

Understanding Why Your Welds Crack – Part 3

Location of Cracks

Cracks can be categorized by their location: weld metal, heat affected zone and unaffected (by heat) base metal.

In our previous two articles we talked about categorizing cracks based on when they occur and in which direction they propagate.  Today on our third and final article on understanding why your welds crack we look at the importance of location. If you want to review or if you missed our previous two articles simply […]

Understanding Why Your Welds Crack – Part 2

Direction of Cracks

In our previous post we discussed categorizing cracks based on when they occur.  If you missed this you can read it at Understanding Why Welds Crack: Timing. As discussed in this previous article, cracks can and should be categorized based on three criteria: Timing – did the crack occur immediately after welding (hot crack), did […]

Understanding Why Your Welds Crack – Part I

Timing of Cracks

Cracks are perhaps the only discontinuity for which there is no allowance.  Most codes require that cracks be repaired.  Crosscheck cracks on some hardfacing applications may be OK, but in general, if a weld cracks it’s a big problem. This problem is time consuming and costly in most cases. When you get a crack you don’t […]

Tips for Passing the AWS 3G FCAW Certification

Passing the AWS Structural Welder Qualification Test (vertical up certification on Flux-Cored Arc Welding) can be problematic for some, but insuring the right procedures and techniques  are used should make things a lot easier.  The good thing about this qualification is that if passed it certifies the welder no just in the 3G position, but […]

9 Maintenance Problems that Cause Bad Welds

Maintenance-related problems are responsible for a large portion of bad welds in every day welding. However, these causes go unnoticed and unresolved because they happen slowly over time. A proper preventive maintenance program for welding machines, CNC cutting tables and other industrial equipment is absolutely necessary. Many of the problems related to maintenance that cause […]

How to Weld Titanium

Titanium is a metal which is silvery gray in color and has about half the density of steel (0.163 lb/in3).  Pure titanium is relatively soft has very low ultimate tensile strength.   For use in structural applications titanium is alloyed with chromium and iron, chromium and aluminum, manganese and aluminum and manganese alone.  These alloying elements […]

Effects of Shielding Gases in GMAW

Using the right shielding gas is essential not only to prevent porosity but to get proper penetration, the mechanical properties you desire including weld strength, and overall weld quality.  In order to select the right shielding gas you need to consider the following: –          Alloy of filler metal –          Material thickness –          Mode of GMAW […]

How to Weld Galvanized Steel

Galvanizing is the application of a zinc coating to a ferrous material. It is done to prevent, or at the very least delay corrosion. The zinc coating can be applied in many different ways including but not limited to hot-dipping, metal spray and electrodeposition.  Similar to galvanized steel is galvanneal steel.  Galvanneal is the process […]

The 3 Biggest Problems with Welding Procedures

Have you ever developed, written, qualified or approved a welding procedure? If you have, what was the reason? To satisfy the requirements of a contract?  To control quality? To improve productivity?  To pass an audit?  To help new welders? As welding consultants, CWIs and welding engineers we see hundreds of welding procedure specifications (WPSs) every […]