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 […]

Is It Time To Retire Your Old Welding Machines?

Those oldies-but-goodies may be costing you money

Thousands of manufacturing shops are full of old welding equipment.  We all want to be good stewards of our money or our company’s money, and we want to make things last as long as possible.  We sometimes even take pride on the fact that we have had a specific welding machine for 20-25 years. Most […]

The Outrageous Cost of Poor Fit Up

You will cringe when you read this

In a perfect world we would have perfect fit up every time.  However, as well all know, this isn’t the case.  We mostly think of poor fit up as annoying and the cause of some delays.  But the reality is it can have tremendous impact on our bottom line.  Or, in many cases, compromises the […]

How Many Inches Of Mig Wire Per Pound

Easily calculate number of inches of wire per package size for any wire diameter

Have you ever wondered, or have you ever been asked how many inches of wire are in one pound of filler metal?  You may have been asked something like: “How many inches of wire are there in a 25LB spool of .035” ER70S-6 mig wire?”  Typically, this questions is asked when someone is trying to […]

Mig Welding With S3 vs S6 Wire

Is ER70S-3 even necessary anymore?

One of the most frequently asked questions is if there is a valid reason to use an ER70S-3 (S3) mig wire versus the more commonly used ER70S-6 (S6) wire.    Both wires belong to AWS Specification A5.18 and can be used interchangeably in most applications because they provide almost identical mechanical properties.  There is subtle difference between the two […]

Calculating Weld Metal Requirements by Hand

When you don't have your Procedure Handbook Tables

If you need to calculate weld metal requirements and you do not have The Procedure Handbook of Arc Welding handy you can do this by hand by using simple geometry. What you need to do is find the volume of weld needed in cubic inches. A fillet weld with a flat face forms a right […]

How To Know If You Are Wasting Shielding Gas

Most manufacturing facilities use  1.5 to 3 times as much shielding gas as they should.  The reasons for this can be found in a previous post: Control Your Shielding Gas Usage. Before doing all the checks to see if you have leaks or other problems there is a simple way to get an idea of whether or not […]

Deposition Rate by Wire Type

A common question in the field is which wire type will provide the best deposition rate.  In one of our earlier posts “Calculating Deposition Rate for Solid Wires” we discussed deposition rates strictly for solid wires.   Here we will talk about deposition rates across wire types – mainly solid wire, metal-cored wire and flux-cored wire.   […]