The Importance of Contact Tip to Work Distance in GMAW

If you look at any of the structural welding codes you’ll notice that contact-tip-to-work-distance (CTTWD) is a variable which must be listed in welding procedure specifications (WPSs).  However, it is not an essential variable, meaning that changes to CTTWD of any amount do not require requalification.   This can seem puzzling to some, especially those […]

Key Components of Effective Welder Training Programs

Continuous learning is something that is very important for both personal and professional development.  This applies to all industries and to all positions.  The welding industry, as many of its counterparts, is challenged with a workforce that is lacking the skills necessary to do the job.  This is driven by the increased demand for welders, […]

The Challenges of Welding in Cold Temperatures

Welding in cold temperatures poses two critical challenges.  First, the brutal conditions welders must endure and second, the performance of steel structures in cold temperatures. Many times we forget about the former by focusing too much on the latter.  If you ever get a chance to talk to welders that have welded in both extreme […]

Who is responsible for determining weld size?

Who determines what size a weld should be?  This is a question we ask many of our customers.  And we never seem to get a straight answer.  In a perfect world, the design engineer should specify all weld sizes and clearly communicate this through welding symbols on the print.  But that is hardly ever the […]

Demystifying Fatigue Fractures in Welding: The 3 Stages of Fatigue Fracture

In today’s article we’ll be discussing a critical aspect of welding which is crucial in ensuring the safety and long useful life of structures.  When engineers conduct a fitness for service analysis of structures they are looking for flaws. These flaws may be cracks, loose bolts, deformations, rust damage (thinning of structural members) and other […]

4 Types of Loading in Welded Structures

There are four types of loading experienced by welds and welded structures.  These types of loading are a function of the strain rate (the rate at which deformation occurs in a material due to an applied load) and the number of loading cycles experienced by the welded member.   The 4 types of loading are: Static […]

Why Welds Fail: It’s never just one thing

Weld failures happen all the time.  Some are more serious than others in terms of cost and potential for property damage and bodily harm.  If a weld failure is considered serious it typically gets a lot of attention. Forensics labs and industry experts get called to determine the root cause of the failure.  It may […]

3 Mistakes that lead to distortion in welding

Distortion caused by the heating and cooling cycles of welding is extremely problematic.  It can place structures out of dimensional tolerance creating costly rework.  In some cases parts need to be scrapped.  Understanding the causes of distortion and the properties of the metal being welded are an absolute necessity for those managing welding operations.  There […]

Pick Your Prequalified Welding Procedures Carefully

Welder performance qualification test for limited thickness.

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 […]