FCAW prequalified welding procedures and their limitations

Dangers even if you follow all the requirements of AWS D1.1

The use of prequalified welding procedures has many advantages as well as many disadvantages.  One danger of using prequalified welding procedures is that AWS D1.1 allows for quite a bit of freedom in weld sizes.  If you look at Table 5.1 –Prequalified WPS Requirements of AWS D1.1/D1.1M:2020 Structural Welding Code (Steel) you’ll see that in […]

6 Levels of Welding Quality Standards

Which one do you fall under?

  We received a large number of email responses and comments to our article from two weeks ago pertaining to weld quality standards. The main question was how to do you determine the minimum level of quality for your products, but also how do you verify you are reaching or exceeding that quality level. Responses […]

How to Determine Acceptable Weld Quality

Certain industries that involve welding of their products have very strict quality standards to ensure the production of sound welds.  Many others however, do not.  They simply weld and unless one of their products fails they don’t pay special attention to welding procedures, detailed inspection of welds or testing the skill (performance) of their welders. […]

How to Become a Certified Welding Inspector

A career as a Certified Welding Inspector (CWI) can be very rewarding.  This certification, which is awarded by the American Welding Society, carries a lot of weight both nationally and internationally.  The main responsibilities of a CWI is to make sure that welding operations are manufacturing products that comply with specified welding codes and standards. CWIs essentially are expected […]

The AWS D1.1 1G Welder Qualification Test

The AWS D1.1 Structural Welding Code (Steel) welder qualification plate tests consists of a groove weld with a 45-degree included angle. The plates are prepared to a knife’s edge and a ¼ in [6 mm] backing strip is used.  The test for unlimited thickness will use plates that are 1 in [25 mm] thick.  Anything […]

Danger of Using the Wrong Shielding Gas for GMAW

In our previous article we mentioned that a customer was inquiring about running their 98% argon / 2% carbon dioxide (98/2) shielding gas on mild steel.  This gas is used on stainless as it maintains the amount of reactive gas (in this case CO2) under 3%.   Our quick answer was “yes, you can weld carbon […]

Which is the best shielding gas for MIG welding?

Today we received two different requests for help pertaining to shielding gas selection.  The first caller requested a chart that tells them what materials can be welded with the different shielding gases that they had.  They wanted a chart that can be provided to the welders to make sure they used the right gas on […]

Basic (Overlooked) Steps to Develop a Welding Procedure

A welding procedure specification (WPS) consists of a series of welding variables and corresponding allowable ranges. The selection of these ranges is very important.  The idea is that if the welder is within all acceptable ranges he or she will deposit a sound weld, provided of course that the welder has the required skill.  The […]

Troubleshooting Erratic Wire Feeding

The majority of troubleshooting calls we receive regarding the GMAW (mig)  process has to do with erratic wire feeding.  This problem disguises itself in many forms, from bad looking welds to lack of penetration.  Sometimes the effects of poor feeding are obvious and easily corrected. However, sometimes these effects are not easy to troubleshoot and […]

7 Ways To Control Distortion in Welding

Distortion is a nasty problem we experience in welding.  Understanding what causes distortion is important in order to be able to minimize or eliminate it completely.  There are physical and mechanical properties that affect distortion susceptibility of materials.  To learn more about this you can read 4 Material Properties That Affect Distortion. As fabricators we hardly […]