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6 Challenges When Increasing Deposition Rates

Want to boost welding productivity? Increasing your deposition rate is one of the most effective ways—but only if done right. This post explains the difference between melt-off and deposition rate, how higher deposition leads to faster travel speeds (and real time savings), and the common mistakes that sabotage these gains. Learn how to avoid costly errors, why simply turning up the amps isn’t enough, and how training and proper welding procedures can unlock major efficiency improvements in your shop.

Welding Procedure Development
Welding Procedure Development: Selecting Welding Parameters

Amperage, voltage, travel speed, and other key variables are crucial for creating a robust welding procedure that ensures sound and high-quality welds.Blog Post Summary This blog post explains the importance of key welding parameters when developing a welding procedure specification. It details how amperage (current) directly influences weld penetration and productivity, while voltage primarily affects bead shape and width. The post also highlights that travel speed is critical, as it impacts weld size, heat input, penetration, and overall weld quality. Additionally, it covers the significance of travel and transverse angles, noting their effects on weld shape and potential for defects. Finally, the post emphasizes the often overlooked but critical role of Contact Tip to Work Distance (CTTWD), explaining how it can drastically alter amperage and potentially lead to a non-compliant or defective weld if not properly controlled.

Burn Through WEld Troubleshooting
Troubleshooting Welding Burn-through

Burn-through is a common welding defect, especially on light gauge materials, that results in holes instead of sound welds. It is often confused with melt-through, which can be acceptable, but true burn-through weakens joints and leads to scrapped parts. The main causes include excessive amperage, poor fit-up, and operator error, all of which make penetration harder to control. Solutions range from adjusting amperage and travel speed to improving upstream processes like cutting and forming, and investing in welder training. By understanding and addressing the root causes, fabricators can dramatically reduce rework, improve weld appearance, and lower overall costs.