Short-arc vs Globular Transfer in GMAW

What is the difference between globular and short-circuit transfer? Short-circuit is a mode of metal transfer in GMAW in which metal is transferred from the electrode to the weld pool via a series of electrical shorts. When the electrode (wire) touches the base material a short occurs and the arc goes out.  At this point […]

7 Variables That Affect Weld Penetration

Complete joint penetration (CJP) welds will have the exact same effective weld size regardless of welding process.

Getting deeper penetration, or at least adequate penetration is very important in welding.  There are a few applications in which we wish to minimize penetration, but in general we always want good penetration.  There are many variables that affect penetration, some more than others.  It is important to know how each individual variable affects the […]

5 Factors that Contribute to Silicon Island Formation in Welds

The formation of silicon islands on welds made with the GMAW (mig) and MCAW (metalcore) processes is very common.  For the most part, these silicon islands are not a problem.  However, if the weld is to be painted, you better remove these islands. Otherwise, they will eventually pop off and leave an unpainted spot in […]

How to Qualify a WPS for Welding Stainless to Mild Steel using AWS D1.6

Macroetch locations for welding procedure qualification of fillet welds.

It is very common to weld stainless steel to mild steel.  But, when it comes to qualifying a welding procedure it can be somewhat confusing.  Do you follow AWS D1.1 (Steel) or do you following AWS D1.6 (Stainless Steel)?   Or is there another code or standard you should use? The answer to this question is […]

Rainbow Colors in Stainless Steel Welding

Are they good or bad?

Different joints will have different levels of admixture (the mixing of weld metal with base metal) . The higher the admixture the more silicon islands will form on the surface of the weld.

We receive several calls about welding stainless and the beautiful rainbow colors, or lack thereof, on the weld and heat affected zone.  Is the tinting an indication of quality?  Are these colors acceptable? Do they show that the weld had enough heat to penetrate?  Why do they need to be cleaned?  The questions are endless. […]

Tips for Passing the AWS 3G FCAW Certification

Passing the AWS Structural Welder Qualification Test (vertical up certification on Flux-Cored Arc Welding) can be problematic for some, but insuring the right procedures and techniques  are used should make things a lot easier.  The good thing about this qualification is that if passed it certifies the welder no just in the 3G position, but […]

How to Weld Titanium

Titanium is a metal which is silvery gray in color and has about half the density of steel (0.163 lb/in3).  Pure titanium is relatively soft has very low ultimate tensile strength.   For use in structural applications titanium is alloyed with chromium and iron, chromium and aluminum, manganese and aluminum and manganese alone.  These alloying elements […]

Effects of Shielding Gases in GMAW

Using the right shielding gas is essential not only to prevent porosity but to get proper penetration, the mechanical properties you desire including weld strength, and overall weld quality.  In order to select the right shielding gas you need to consider the following: –          Alloy of filler metal –          Material thickness –          Mode of GMAW […]

How to Calculate Deposition Rate for Solid Wires

A common question that is asked when manufacturers are trying to determine costs associated with welding is: How many pounds of wire can I deposit per hour? Or, how many pounds of wire can I deposit at a specific amperage or wire feed speed?   There are charts to help you determine this, but it’s always […]

Welding Cast Iron

Cast iron is not impossible to weld, although many that attempt to do so end up with cracked welds. The reason welding cast iron is a big challenge is that it contains up to 4% carbon.  This is an insane amount, considering that any material with a carbon content above 0.30%  is already considered “high […]