There are many ways to reduce costs in welding operations. Here are 11 ways to get you started:
1. Eliminate Overwelding – Make sure welds are properly sized by following what is called out on the print. Don’t have prints? Develop them! The savings can be huge.
2. Reduce the amount of reinforcement – Multiple pass welds on a groove joint typically end up with a certain amount of reinforcement. The goal is to be just above flush to prevent underfill. However, a 1/8″ reinforcement will not be better than a 3/32″ or even a 1/16″ in most cases.
3. Use proper polarity – In applications were penetration is not important or desired, such as hardfacing, use DC- to achieve greater deposition rates.
4. Reduce gaps – Gaps increase the volume of weld needed.
5. Control flow rates – For processes that require shielding gas make sure no more flow than necessary is used. Too much flow will waste gas and can even create weld defects.
6. Increase electrode diameter – Whether you are stick welding or mig welding, consider using a larger electrode to achieve higher deposition rates.
7. Consider intermittent instead of continuous fillets
8. Select the right process – Don’t TIG weld if MIG will do. Sticking? Can you use a wire process?
9. Properly position the work for optimal efficiency – ideally we want to weld in the flat or horizontal position. Welding out of position (vertical up, overhead, 3 0’clock, etc.) reduces deposition rates because we are limited in puddle size.
10. Use fixtures
11. Use procedures and processes that eliminate spatter – Consider using 90/10 gas instead of C25 or 100% CO2. Consider pulse welding instead of CV welding.