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 […]

What is Your Biggest Welding Problem?

Welding is a very complicated industrial process with many different variables.  Because of this there are an innumerable amount of problems we can experience when we weld.  From porosity and spatter to cracked welds, welding problems cost us a lot of money.  In some cases welding problems are severe enough to cause significant delays adding […]

Which Arc Welding Process is the Most Efficient?

This question can be answered very quickly.  Gas Metal Arc Welding (GMAW) and Submerged Arc Welding (SAW) can have 98-99% deposition efficiency.  However, the question is a bit more complicated since when we talk about efficiency we don’t just care about deposition efficiency (how much of the electrode becomes weld metal).  What we care about […]

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 […]

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 […]

The Reason Behind Minimum Fillet Weld Sizes

It's not what you think

Have you ever noticed that there are design rules that prohibit sizing a fillet weld below a certain size for a given thickness of material? If you look at AWS D1.1/D1.1M:2015 Structural Welding Code (Steel) you can find this on Table 5.7.   If you happen to own a copy of AISC 360-16 Specification for Structural […]

Modes of Metal Transfer: Pulse

Pulsed spray refers to a GMAW mode of transfer in which metal droplets are transferred through the arc with changes in amperage produced by the power source.  The power source provides a pulsing peak current that raises the amperage above the transition current and allows for axial spray transfer.  This peak current is only applied […]

Modes of Metal Transfer: Spray

Spray is a mode of metal transfer in which a fine spray of metal droplets are projected axially from the tip of the electrode to the work.  These droplets are smaller in diameter than the electrode.  This mode of transfer is characterized by high wire feed speeds (high amperage), high voltage and consequently high heat […]