5 Common Mistakes Made When Estimating the Costs of a Welding Job

When bidding jobs several fabricators end up calculating their costs associated with welding and then double that number to be safe.  In some cases, that isn’t even enough.  It is important to have a clear understating of how to translate the amount of welding to be done to actual manufacturing costs.  One of the biggest […]

Control Your Shielding Gas Usage

If you own or run a business in which welding is an integral part of the manufacturing process you know one of your recurrent expenses is your shielding gas.  Very few manufacturing facilities, big or small, have excellent control of gas usage.  Most end up using twice as much than necessary, and in some cases […]

Calculating Weight of Weld Metal Required

Estimate pounds of welding electrode necessary to complete a job

Calculating weld metal requirements seems complicated but for the majority of applications it should not be. Short of having a computer program that calculates this for you, the easiest way is to use the tables found in The Procedure Handbook of Arc Welding. Table 12-1 provides data to calculate weight of weld metal required per […]

Importance of Macro Etch Testing of Welds

Lack of fusion cannot be detected visually. The image above shows a macroetch of a fillet weld showing that lack of root fusion.

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 […]

Bigger (Weld) Is Not Always Better

When it comes to fillet welds, bigger is not always better.  A fillet weld is easy to measure, simply take out your fillet weld gauges measure it.  However, there is an incorrect assumption that a bigger weld (as measured with a fillet gauge) is always stronger than a smaller weld. Before we get into this […]

12 Ideas to Reduce Welding Costs

Controlling costs associated with welding operations does not have to be complicated. Yet, many fabricators miss out on savings substantial amounts of time and money simply because they are too busy to take some time to implement cost reduction initiatives.  Some of the ways in which costs can be reduced are presented below.  Some of […]

Non-Value Added Activities Affecting Welding Costs

Many fabricators struggle to get a grip on their welding costs.  The best they can do is try to find suppliers that will sell them their consumables, gas and other raw materials at a lower price.  Those who try to reduce costs by being more efficient soon realize that simply speeding up welding is not […]

Pick Your Prequalified Welding Procedures Carefully

If you work with AWS D1.1 you are probably familiar with the use of prequalified welding procedures.  The use of prequalified WPSs provides many benefits to the fabricator, one of which is costs savings due being exempt from having to perform costly testing to qualify the welding procedure.  However, if you are looking to save […]

Welding Cost Reduction Revisited

Many of our customers realize that there is a great potential for reducing costs in welding operations.  Yet, not many are willing to attack this area of manufacturing.  The reason for this is that welding is a very complicated industrial process.  It has many variables that come into play which determine quality and productivity.  So […]

5 Ways to Increase Welder Efficiency

In our many years of working in the welding industry we have come across some phenomenal welders.  We continue to be impressed by the level of skill of quite a few of these men and women.  Unfortunately, many business owners allow this skilled labor to be underutilized.  Welder efficiency, which also goes by other names […]