Welding News - Welders Analysis

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Geeking out about welding

2008-01-21T17:43:00.000-08:00

Hey, you have to like a science fiction movie that mostly features welders.

A roundup of online welding tutorials

2007-12-16T07:36:00.000-08:00

I have checked these out, and recommend the following spots for learning more about welding. Sometimes, you'll have to use multiple sites to get a good grasp on all the aspects of mig welding.

Of course, Amazon welding books are an excellent way to get started. I have several of these. They have an enormous selection of welding books (tried lately to find anything good at the local bookstore?). Check them out.

I like the Expert Village's mig welding video series. Mike Rogers does a good job and there are 15 different videos. I've never been one for overly long online videos, but these are well done and not long enough that you'll get the urge to browse away.

The Fabricator has a good one, "Mig welding -- the basics and then some". Check at the end; they link to even more how-to mig weld articles.

The Instructables is a newer site (at least to me) with a good illustrated guide to mig welding. They qualify it with "This instructable is not intended to be THE definitive guide on MIG welding, for that you might want to seek out a a more comprehensive guide from a professional. Think of this instructable as a guide to get you started MIG welding. Welding is a skill that needs to be developed over time, with a piece of metal in front of you and with a welding gun/torch in your hands."

(And that's good advice for any online learning. The web is a good place to start, but in no way should it be the end-point of your welding training journey).

What kind of jobs are welders getting, and where?

2007-11-10T15:53:00.001-08:00

Projected to 2006 (so just a bit out of date, but still pretty solid), the American Welding Society is saying that there will be 393,701 welding jobs in the United States, most of them in a few states, and many of them concentrated in just a few industries.

Fabricators are the single largest employer of welders, at 10%+ of the total. That bears out what many people see--the lines of fab shops in any industrial district in any town in the country bear witness. These are pretty good jobs, but are often smaller companies which have both advantages and drawbacks.

7% of welders are self-employed. It's nice working for yourself, but it can be stressful not knowing who's writing you a check in two months, once a gig is up. After that, we are looking at automotive ( both body shops and repairs and manufacturing), about 6% and then construction for 3%.

Better in Texas?

Near-bouts, two out of five welders were employed in six states: Texas, California, Ohio, Pennsylvania, Michigan and Illinois. Pretty much tracks to the largest states with manufacturing bases, but in this economy a good hand with a welding rod can find work anyplace.

Welding videos

2007-11-03T13:44:00.001-07:00

Over at Expert Village, they have a nice series of mig welding videos from Mike Rogers that you should check out. There are 75 related videos linked from there, so it's worth a look.

Miller giving away $17,000 worth of welding swag

2007-10-28T07:29:00.000-07:00

Check out http://www.millerwelds.com/ultimate.

The grand prize winner also getsa special training session with a Miller expert conducted at the closest Miller Regional Training Center, with the travel costs included. To get in on this, you gotta go to your local welding distributor and get a promo code. Then you register that at the link above. The package includes, among other things:

Trailblazer 302 welder/generator
Suitcase X-TREME 12VS wire feeder
Millermatic 252 all-in-one MIG welder
Spectrum 375 X-TREME portable plasma cutter
Dynasty 200 DX AC/DC TIG welder

Gives you an excuse to go to shopping, even if you' don't win the contest.

Spectra-Curtain transparent welding curtain allows outside light into a welding booth to help the welder’s vision

2007-10-20T07:53:00.000-07:00

Looks like a nice, portable solution for quite a few welding applications.

The Spectra Orange See-Thru Curtain filters welding arc images and all far U.V. radiation and blue light, while transmitting outside light into the welding booth.

The company said the Spectra Curtain is designed for low to high amperages in electric arc welding, and can be used for MIG, TIG, arc, plasma and other high amperage welding arcs. It is designed for heavy duty workplaces.

New welding standard listed for aerospace manufacturing

2007-01-21T07:19:00.000-08:00

News...

A new American National Standard from the American Welding Society (AWS) covers resistance welding methods for metals used in the manufacture of aviation and aerospace equipment. AWS D17.2/ D17.2M:2007, Specification for Resistance Welding for Aerospace Applications, also details criteria for machine and procedure qualification and the inspection of aerospace hardware.

Lincoln's "How I did it" - some good stuff, but more detail needed

2007-01-17T20:20:00.000-08:00

If you grab a subscription to Lincoln's excellent iWeld newsletter, you got a link to the "how I did it" page of their website.

The page features welding projects from dozens of welders. The projects range from race car frames to hay bale handlers to bed frames to cactus shaped mailboxes. What would be really nice would be more project specifications to go along with the photographs. They have a nice start, but without the descriptions and project info, it's lacking.

Free tungsten welding PDF for download

2007-01-09T18:57:00.000-08:00

Check it out.

The book is self-described as: "intended to assist welders in selecting and preparing one of the most important and frequently overlooked welding process variables: the electrode. Welders can spend thousands of dollars on welding equipment, but if they do not select and prepare their electrodes with this less expensive process component properly, then their welding results can be poor, inconsistent, or problematic. This guide will help eliminate this variable as a concern in your welding and make it an asset."

Lincoln announces material safety data sheet program

2006-12-17T14:46:00.000-08:00

This is a particularly good idea. You can sign up at the Lincoln Electric website for updates on all changes to Lincoln Electric's Material Safety Data Sheets. Lincoln will e-mail you weekly with a list of MSDS sheets that have been changed.

Product classes include Aluminum, Cast Iron & Non-Ferrous; Cut Length; Hardfacing; Mild and Low Alloy Steel; Flux-Cored; Mild and Low Alloy Steel Stick; Mild Steel and Low Alloy MIG; Miscellaneous; Stainless Steel; Submerged Arc. You can also elect to get website updates for Lincoln's products as well as its great welding safety page.

It's free -- and you can sign up right here...

Engineering Departments from Over 200 Companies to Benefit From Cost-Saving Online Weld Testing Simulations

2006-12-07T16:10:00.000-08:00

11/28/2006 - Columbus, Ohio -- Joining high performance computing (HPC) applications with small- and medium-sized companies is one step closer to reality as the Ohio Supercomputer Center (OSC) and the Edison Welding Institute (EWI) announced a partnership agreement today. As part of its innovative Blue Collar Computing initiative, OSC will provide remote portal access of HPC systems and software to EWI welding applications—a tremendous cost-saving resource that will reach engineers at over 200 companies.

Welding involves the complex interactions of a high number of physical processes. Integrated numerical simulation tools are needed to improve the performance of welded structures. Through OSC’s HPC application interface, engineers will easily be able to input product dimensions, welding process parameters and other specifications to conduct complete online simulations of welding procedures to determine the strength and viability of its prototypes.

The entire story is available at Edison Welding Institute...

Fatigue Crack Repair

2006-12-04T17:22:00.000-08:00

This thread in the Google Welding group is a pretty lively discussion on how to repair a structural crack in a chassis. (In this case for a backhoe).

I have a question of curiousity here. I have a backhoe with a fatigue
crack in the chassis. The chassis is made from rectangular mild steel
box section. The crack is where a piece of 6" x 2" x 1/4" box section
is welded to a piece of 4" x 2" x 1/4" box section at 90 degrees. The
crack is in the butt welded section and is about 1" long.

Someone else has tried to fix the crack once before. They appear to
have welded up the crack, then created a broad "patch" of weld metal
about 1" wide and 1/8" thick across the affected area. Their weld isn't
messy, but there's a lot of weld metal present. I don't know if this
was a sensible way to fix the crack, but it is just starting to
reappear again. I wonder if they didn't get complete penetration and
left a tiny depth of crack which has helped the crack to grow again.

The responses are all good, but the best one seems to capture the issue: drilling out the ends to relieve stress points.

One thing you're not mentioning that I consider a critical part of any
crack repair is to drill out the ends of the crack. You can plug weld
those holes as part of the repair process, but it is essential to get
rid of the stress concentration points at the end of the crack so it
does not continue/come back.

"TIg, Mig, or Fluxcore - now we have the welder's attention"

2006-11-13T17:59:00.000-08:00

That was a radio ad I heard several times today from Tulsa manufacturer John Zink Company. They promised quite a lot, but then promised a bit more to the right welder. Are you the right welder? They want people who are good at math. Who can read bluprints or CAD prints without having their hands held. This is the kind of skillset welders who really want stability and advancement.

The company advertises a boatload of welding opportunities on its website. Are you the right kind of welder? The kind willing to work as hard with your head as you are your hands? It's time to hone up more skills than just running a good bead. These are the kinds of jobs that are good for welders.

It's a good market for welders pretty much anyplace -- today. Companies like Zink who provide good benefits and don't put you to work in dirty, hot shops are the ones hiring the guys willing to make that extra effort.

2006-10-23T20:21:00.000-07:00

Welder

Nifty video of a robotic welder, courtesy of Youtube...

Welding job market continues to be red-hot

2006-09-22T18:09:00.000-07:00

If you're a welder today, you're in demand. Welding schools can't churn out enough new welders to meet demand. Want ads feature pages of welding want ads. I've heard commercials on local radio that promise signing bonuses to welders. Articles around the country point to it -- demand is high and supply is low, especially for the kind of salty, experienced hand that can do the job right.

What does this mean to you? Depends on where you are in the cycle. If you're new, it's a great time because jobs will hunt you instead of you hunting them.

Although job growth in the welding profession is slower than average, according to the U.S. Bureau of Labor Statistics, there are plenty of employment opportunities. New recruits are needed to fill positions vacated as the workforce retires, according to the Great Falls Tribune. Welders are paid an average of almost $15 an hour, so the market is good.

If you're a veteran, it's also a time to leverage your experience. You can negotiate at this point. You can get more out of it, and not just in base pay. You can get perks, bonuses, and benefits. If there was a company you always wanted to work for, you can angle into it now.

In all, even with job growth slowing, there are relatively fewer welding guys out there. Take advantage, though -- the pendulum is always swinging.

Researchers create welding setting algorithm

2006-09-01T16:17:00.000-07:00

Researchers at Cardiff University’s Manufacturing Engineering Centre have developed an algorithm to work out the most efficient settings on welding systems and for the design of springs. Researchers claim the algorithm can be used to consider as many as to 3,000 variables, and is faster than existing methods of calculation. See more information over at www.weldingdesign.com.

A roundup of posts in Google's welding usergroup...

2006-08-19T18:50:00.000-07:00

I like to browse this for convversation, tips and info. This is the most recent & interesting welder's conversations over there....

Spray mode http://groups.google.com/group/sci.engr.joining.welding/browse_thread/thread/20a274da3401a2a
A little diamond wheel grinder that I put together http://groups.google.com/group/sci.engr.joining.welding/browse_thread/thread/cb2809f3534ee055
Air Compressor tank welding question
http://groups.google.com/group/sci.engr.joining.welding/browse_thread/thread/8db9c9f7c0745bf
Welding silicon bronze -- am I doing something wrong? http://groups.google.com/group/sci.engr.joining.welding/browse_thread/thread/d17009b663083576

Environmentally friendly MIG welding?

2006-08-13T06:50:00.000-07:00

Welding is a fact in modern life. It touches just about everything everyone drives in, lives in, works with, or enjoys, but it isn't exactly "green" or optimized to save energy. It emits greenhouse gasses, and whether or not you believe that this is a big deal (I do), it's a good idea to conserve power and reduce pollutants from any activity done as broadly as welding is. The big heaping amounts of carbon dioxide MIG and GMAW use as shielding gasses and the power-hungry welders are a good market for someone who wants to market an idea, and maybe do some good.

The Ferret website is reporting on Australia's Centre for Energy and Greenhouse Technologies efforts to inject some efficiency into welding by plunging $450,000 into a new company, MIGfast. They're trying to make welding contact tips that help make a weld take less time, which would naturally reduce energy use and gas emissions. The claim is that these tips would reduce the time by as much as half.

If they can do it, I know plenty of welders who'd use them whether they care about greenhouse gasses or not.

Arc performance issues

2006-07-27T19:28:00.000-07:00

According to Lincoln Electric, these are the top concerns welders have withb arc performance are: (1) excellent starting performance, (2) the ability to weld at low amperages, (3) crater fill capabilities to end the weld with precise control and without the high frequency reestablishing, (4) a smooth, stable arc with minimal AC rectification across a wide welding range, and (5) expanded balance range to narrow the cleaning zone adjacent to the weld.

Tons of good info, and a bit of salesmanship can be found at Lincoln Electric.com. They use it to sell their new TIG model, but it's not all salesmanship. It's solid.

Need AWS quality procedures written up?

2006-05-15T21:27:00.000-07:00

If you do contract work that requires American Welding Society (AWS) standards, then it's a matter of time before a welding inspector or engineer asks you for your welding procedures and certifications. The folks over at weldingprocedures.com can help by providing a to-spec procedure document. Your welders can be qualified using the AWS D1.1 Steel Welding Code along with your procedure.

The procedure costs $35 and is accepted on any project worldwide where AWS is specified.

FCAW (Flux cored arc welding) General WPS using E71T-1: Good for all common carbon steels and approved for all joints in the AWS D1.1 Code.

SMAW (Stick Welding) General WPS using E7018: Good for all common carbon steels and approved for all joints in the AWS D1.1 Code.

GMAW (Mig welding) General WPS using ER 70S-6: Good for all common carbon steels and approved for all joints in the AWS D1.1 Code.

Custom WPS For this procedure you must send us all pertinent information including electrode type, material to be welded, joint design, machine settings you use and any special conditions. The only condition is that the procedure complies with processes, electrodes and joint configurations that are pre-qualified by an AWS welding code such as AWS D1.1-2002 Welding Code for Steel.

Check it out over at www.weldingprocedures.com.

A cool, new welding helmet from Millerweld

2006-05-12T19:56:00.000-07:00

Miller Electric offers an addition to the Big Window Elite Series: the Inferno.

For professionals and hobbyists alike, the Inferno provides the maximum viewing capacity, is lightweight, comfortable, and offers light-state clarity and exceptional battery life. It features the Performance Series Lens technology, including replaceable batteries with solar assist for exceptionally long life (3,000 hours on MIG) with no recharging required. The Inferno easily handles low-amperage DC inverter and TIG applications (5 amps and below) and has a reaction time of 1/20,000 second. For more information visit millerwelds.

Picking one of these up is a definite thing on my list...

Industrial welding programs

2006-05-03T15:52:00.000-07:00

Thomson offers a good training program for people who work on the periphery of welding in an industrial environment. Here's the description from their site...

Industrial Welding Training helps plant maintenance workers develop a working knowledge of and learn the theory behind gas and arc welding techniques and equipment, and the cutting of iron, steel, pipe, and nonferrous metals.

Trainees receive an overview of basic mathematics, print reading, and safety, followed by the fundamentals of metallurgy, electricity, and weld inspection. Since welding demands repeated hands-on practice, make sure your employees have easy and frequent access to oxyacetylene and shielded metal arc (stick electrode) welding equipment.

Program graduates will develop the expertise to:

Select the proper tip for gas welding.
Read basic welding prints.
Explain the start up procedure for arc welding.
Describe the various uses of Gas Tungsten Arc Welding.
Discuss the use of Gas Metal Arc Welding.
Select the proper shielding gases for welding.
Describe the procedures for the inspection of welds.
Discuss the procedures for nondestructive testing of welds.

Welding rod litigation status report (from the defense side)

2006-04-29T19:34:00.000-07:00

The welding fumes battle continues. Here's the score, according to www.weldinginfonetwork.com, a website sympathetic to manufacturers in this battle (they call the welding rod litigation "ill-conceived business venture for plaintiffs’ counsel."

According to a PDF released on the group's site...

In recent months, plaintiffs’ counsel have dismissed thousands of their cases
New filings have decreased as well -- a decline of approximately 25% of welding fume claims
pending in state and federal court, and more claims are being dismissed weekly.
40% of plaintiffs were never diagnosed with any neurological condition
70% of the allegedly sick claimants have never sought medical treatment
10 of 11 cases tried to juries have resulted in defense verdicts (the one loss was in pro-plaintiff Madison County Illinois)
the federal court presiding over almost half of the welding claims pending
in the U.S. (the MDL court) has established a case administration plan to re-evaluate all
of the pending federal cases
Six recent studies have confirmed that welders are not at increased risk of developing Parkinson’s disease, parkinsonism, manganism, or other, similar movement disorders.

Take this as you will, it is factual as best I can tell, but obviously biased in one direction.

Welding Defects - How to Prevent Them!

2006-04-19T04:19:00.000-07:00

Pulled this from our friends over at Rodovens.com.

There are welding defects that are sometimes overlooked or not considered. Each welding project requires careful considerations. They include:

The process, the type of welding i.e. stick, MIG, TIG.

The composition of the base metal and thickness.

The welding position, i. e. flat, vertical, horizontal, overhead.

The weld joint and type.

Electrical supply and equipment.

And finally, the welding techniques to be used.

To minimize the chance of welding defects be sure to consider 1) the travel speed of the pass; 2) the size and type electrode; 3) machine settings; 4) make sure the welding is done in accordance with the plan and the current conditions.

Read the rest here...

Steel prices on the rise, welders feel the pinch

2006-04-11T15:54:00.000-07:00

According to the Oxford, MS Sun Herald, steel prices are set to rise for the next few months. The paper says that "Stock market investors are speculating that mills may institute a $10 to $30 per ton price increase this month, according to the online business-news service briefing.com. In the Gulf Coast region, the demand is high for the building material because of back-to-back busy hurricane seasons."

Steel is vital because it's a key building material for casino resorts, bridges, high-rise condominiums and concrete houses.

For welders, fabrication shops and metalworkers - not to mention the companies that hire them - this is a significant issue. Rebuilding from Hurricane Katrina (and the busy preceding hurricane season), low inventories, and global demand are driving supplies down and prices up. It's going to cost more to build things, and that will affect how many projects are available to welders and fabricators.

We'll keep an eye on it...

One problem with building new nuclear plants? Lack of qualified welders...

2006-04-09T20:39:00.000-07:00

According to a recent story in the Arizona Daily Star, as the nuclear industry stirs with the first plans in 30 years to build new power plants in the United States, there's an unexpected hurdle to be overcome: There may not be enough nuclear engineers around anymore to build and run them.

And that goes for highly specialized craftsmen -- like welders.

According to the Star article, David Lochbaum, director for nuclear-safety projects at the Union of Concerned Scientists, said it's not just the lack of experienced engineers, but other specialists who will be required to build the plants.

"When you move beyond the blueprint, it requires welders and pipe fitters and others with specialized knowledge," he said.

Make your own 180 Amp TIG Welder...

2006-03-29T15:50:00.000-08:00

Really fascinating link I'm throwing at you today involves Dave Barret's quest to make his own TIG welder from scratch. This project is built around TTL and CMOS logic to keep it simple, repeatable and easy to trouble shoot.

Here's his list of features:

1/ AC-DC welding variable via two thumbwheel switches from 1% (all Negative) right through full range of AC to 99% (all Positive).
AC frequencies available from 15 to 400 Hz
2/ Pulse Frequencies fully variable from .3 to 10 Hz This does away with having to pulse the foot peddle on thin materials.
3/ Variable control for Maximum Welding Current available to the Foot peddle control.
4/ Variable Start Current (period of higher current available (higher than max set) for short time heating of thick materials)
5/ Variable Start time for above.
6/ Variable End Current (Crater).
7/ Variable End Current time.
8/ Variable Gas Start time.
9/ Variable Gas End time (Dwell).
10/ HF Arc Start.
11/ Opto Interupter / Potentiometer foot peddle current control.

The page is packed with photos, schematics, even printable PDF's. It's a great piece of work.

Airgas expanding in Wisconsin; buying Airtec

2006-03-14T18:04:00.000-08:00

According to MSN, Airgas, which has about 600 distributors nationwide, is buying Airtec. Inc. Airtec is based in the midwest, where Airgas is trying to expand its business base. The consolidation in the gas business continues...

MG welding offers productivity gain analysis online tool

2006-03-09T17:08:00.000-08:00

MG Welding has a nifty welding productivity calculator you can play with over on their site.

Just enter your data and click "calculate" to estimate the gain in plate cutting productivity (inches cut per shift hour) when using MG Systems' technology. The application used is 1/2" thick mild steel plate (8' x 20') with 160 parts and 320 pierces, cutting 10 shifts per week.

The site warns that actual results may vary based on your application. It's more of a calculate for ballpark range, in my opinion, but very worthwhile for theorizing. I did a basic calculation and it spat out a 72% productivity gain, given my numbers.

Plate Processing Productivity Gain Estimator

Productivity Gain using MG technology:
72%

Based on the following:
	Current Method	MG Advanced Technology

Process Selection (ref only):	Plasma	Plasma
Cutting Process Speed (IPM):	140	160
Number of torches:	1	1
Rapid Traverse Speed:	500	1000
Torch Lifter Speed:	180	880
In-Cycle Portion of Shift Time (%):	40	45
Cutting Support Table Cleaning:	4 hours / week	5 minutes / Day

Troubleshooting the GMAW Process: This month's AWS Journal

2006-02-08T16:24:00.000-08:00

Although many people tout gas metal arc welding (GMAW) as an "all-in-one" solution, that doesn't mean it's a magic remedy for eliminating your welding problems. this article examines common pitfalls encountered during the normal course of GMA welding, along with trusted ways to correct them. More here...

Porosity
Porosity is a small pocket of gas caught in the weld metal that can appear at any specific point on the weld or along its full length. This discontinuity — whether internal or on the surface of the weld bead — significantly weakens the structural integrity of any weld. Inadequate shielding gas coverage is a common cause of porosity and is easily corrected by taking some or all of the following measures.

First U.S. Jury Verdict Linking Asbestos From Welding Rods to Mesothelioma and Lung Cancer Affirmed by New York Appeals Court

2006-01-18T18:39:00.000-08:00

Well, the back & forth between trial lawyers and welding industry lawyers continues. The only sure thing is that lawyers will get rich. For the sake of all the guys out there welding, I hope that they're wrong and that the fumes are safe. I really do. But if they aren't, then this is for the better.

NEW YORK, Jan. 9 /PRNewswire/ -- In the second major verdict against the U.S. welding industry in little more than a week, a New York State appeals court on Dec. 29th affirmed the first-ever jury finding that asbestos-containing welding rods, sold in the billions up to the early 1980's, had caused lung cancer and mesothelioma, Attorney Jerome H. Block of the nationally known mass toxic tort law firm of Levy Phillips and Konigsberg, LLP announced.

The New York Supreme Court, Appellate Division, First Department, in a published decision, upheld the July 2003 jury verdict in favor of, Angel Gomez, who died following the trial, and the late Daniel Tucker. Both men worked with and around asbestos-containing welding rods. The jury awarded Gomez a total of approximately $3.19 million against Lincoln Electric Company ("Lincoln"), reduced 25 percent since Gomez was a cigarette smoker. Tucker's estate was awarded a total of approximately $3.5 million split between Lincoln and Hobart Brothers Company ("Hobart").

Read the rest over at Yahoo...

Welders median earnings...

2006-01-08T14:26:00.000-08:00

In case you were wondering, the United States department of Labor says that Median hourly earnings of welders, cutters, solderers, and brazers were $14.72 in May 2004. The middle 50 percent earned between $11.90 and $18.05. The lowest 10 percent had earnings of less than $9.79, while the top 10 percent earned over $22.20. The range of earnings of welders reflects the wide range of skill levels. Median hourly earnings in the industries employing the largest numbers of welders, cutters, solderers, and brazers in May 2004 were:

Motor vehicle parts manufacturing	$16.47
Agriculture, construction, and mining machinery manufacturing	14.12
Architectural and structural metals manufacturing	13.98
Commercial and industrial machinery and equipment (except automotive and electronic) repair and maintenance	13.45
Motor vehicle body and trailer manufacturing	13.45

Back after a holiday break!

2006-01-04T19:35:00.000-08:00

Just a quick note that we're back here at the Welder's Corner after a holiday vacation. I hope you strike a clean arc and run a good bead in 2005!

American Welding Society offers full catalog in PDF, print formats

2005-12-26T17:07:00.000-08:00

If you're looking to catalog some of the services available from the AWS, I would suggest its 2005 catalog (until the 2006 version hits, anyway). Check it out here. You'll need PDF reader to see the online version, but you can get that at www.adobe.com.

American Welding Society's Free Online CWI Verification Service

2005-12-19T14:47:00.000-08:00

AWS is touting a free new online service: its CWI (which stands for Certified Welding Inspector) Verification Service.

It's a web based service with a lot of appeal because you can get answers instantly in a browser. Here's how it works: enter a CWI number below. This number can be found on a wallet card or wall certificate produced by the inspector. The search will return the certification number, a name, and an expiration date for that individual.

The first four digits of the CWI number are the year and month of original certification. For example, 9603xxxx means that the inspector was certified in March of 1996.

The next three digits of the number are unique and the last digit of the CWI number indicates the level of certification. A last digit of ‘8’ means that the individual is a Senior Certified Welding Inspector (SCWI). A last digit of ‘1’ or '3' means that the individual is certified as an AWS Certified Welding Inspector (CWI). A '2' or ‘4’ means that the individual is certified at the level of Certified Associate Welding Inspector (CAWI).

See it here.

The Certified Welding Inspector (CWI) certification is widely recognized in the welding industry. The CWI examination is made up of three parts: Part A: Fundamentals – consisting of 150 questions, Part B: Practical – consisting of 46 questions and Part C: Code Book – consisting of 46 questions.

Bargain Shopping - How to get a good price for your welding purchases

2005-12-15T14:27:00.000-08:00

So, if you're looking around online for a better deal on that Mig you just can't live without, where do you go first? You can look for bargain MIG welders on eBay easy enough; just hit eBay.com and do a search for what you're looking for. Besides the used welders offered by individuals, there are tons of eBay stores with new equipment. I have not done business with any of these people, but they are rated by their user feedback, and that's typically-- but not always -- a good indicator. I'd suggest that you use a credit card, not a debti card, for these purchases, especially with any online business. Your credit card company can easily help you dispute the charge if what you got wasn't what you were promised.

One place that I like a lot is Froogle, a service from Google. What's wicked cool about Froogle is this: you can enter a search term in Google, see information on it from the Google site, and then click the Froogle link to see products offered. For instance...

I entered welders into Froogle. Got a bunch of different results. However, I was really looking for a Hobart 500425 Tigmate AC/DC Tig Welder Kit. The results? This page, with a ton of different stores offering the weider online and all their prices. See it here. I got 3 pages of results and prices ranging from $1560.75 to $2,500. Quite a difference, and Froogle, like a lot of shopping engines, makes it easy to get price comparisons. Some of the older ones made stores pay to get in, so they only really are ads for a limited number of stores. Froogle's free, so everything's in it.

I've used it for everything major I've purchased for a while now, especially if I'm buying stuff over the web. Works like a charm.

Is the AWS Welding Journal out of Step?

2005-12-08T20:16:00.000-08:00

Over at the AWS forums, this question came up. They've noticed that more and more of the AWS content is aimed at management and engineers rather than at welders.

I find all of it interesting, but as one poster put it...

"Is it just me or is the welding journal moving further out of the main stream of the industry? It seems to me that there is increasingly less information of any practical use to "everyday, real-world situations."

Most of the welding that I run into as a mobile contractor involves repair and maintenance work on heavy equipment and some tank and pipe work. It has been a while now since I have seen any articles on these topics. For example a recent cover story "Brazing in Space", while interesting, does not benifit me in the slightest. My absolute personal favorite was the article entitled "Tips from the Pros" with such indespensible advice as "make sure you get a good ground" and "Make sure there are no flammable materials in the area!" Please!! If you do not know this already then you are a Darwin Award just waiting to happen. Who was this little gem marketed to anyway?! A grade school special-ed class perhaps!? Amazingly, all three welders featured said almost the same thing.

I understand the purpose of the journal is to "advance the science, technology and application of welding etc.,etc." but does this mean that there will be no information geared towards the more common, everyday processes.

Please let me know what you guys think. If I am in the minority position on this issue then I will gladly keep my mouth shut, but I don't believe that I am the only one who feels this way."

U.S. Army Purchases SGI and VRSim Immersive Virtual Reality Welding Trainer Systems

2005-12-05T19:24:00.000-08:00

This is just about the coolest...

Since you can't use oil based products on Acetylene torches, what is the best way to keep torches and tips clean?

2005-11-27T08:16:00.000-08:00

Tips are cleaned with little kits that contain a file and some little toothy wire rods. You simply burnish the end of the tip with the file and push the appropriate size wire rod down the hole or holes in the tip.

Do not use any thread sealer. Just keep everything clean and completely free of oil or grease. Typically, the torch head to torch body connections are hand tight only. The torch to hose body connections are wrench tight but not incredibly so. Barely tight enough to not leak is what you want.If your threads are dirty use a tooth brush or something with soft bristles. Brass is soft.

Welding the Roswell UFO...

2005-11-27T08:11:00.000-08:00

In a funny moment in the Google Welding Newsgroup (which I read often), a poster threw this out...

My granddaddy was living near Roswell in 1947 and now he died and I found some parts of the Roswell UFO in his old barn, some odd alien device.

How can I weld these UFO parts, it's a unknown alien material ???

I want to repair the alien device and sell it for big $$$ !!! If you help me and it works, I will pay anyone who helped me $1 Million !

As you can imagine, the responses ranged from humorous to dismissive.

Harris Calorific, Airgas Join Forces for Laser Offering, Including New Configurator

2005-11-16T15:56:00.000-08:00

This press release comes from Business Wire.

CHICAGO--(BUSINESS WIRE)--Nov. 15, 2005---In a joint press conference at the 2005 FABTECH International(R)/AWS Welding Show today, Gainesville, GA-based Harris Calorific, Inc. and Airgas, Inc. (NYSE:ARG) announced an agreement to jointly market gases and gas control equipment for carbon dioxide lasers used in materials processing.

With this agreement, Airgas has chosen to exclusively market Harris Calorific laser gas control equipment. Airgas, in turn, will have exclusive use of a new customized Airgas Laser Gas Configurator developed by Harris Calorific. The Configurator will help Airgas' nearly 1,000 sales force select the right gases and gas handling equipment for their customers' laser equipment.

The Configurator is programmed with data on more than 600 different carbon dioxide lasers and can quickly determine the required lasing, purge and assist gases, pressure, flow, and gas control equipment, based on the laser, the types of materials being worked and the laser runtime.

"Our combined knowledge of the laser marketplace will help Airgas and Harris better serve laser cutting operators, so they can be more productive U.S. manufacturers," said Tom Thoman, vice president - gases, for Airgas, Inc. "This will be an important element in the full product offering that we bring to our laser cutting customers."

"We are excited about joining forces with Airgas," said David Bell, manager - Special Products Group for Harris Calorific, Inc. "Based on Airgas' extensive customer base, we know they work with many existing laser customers. Our new Airgas Laser Gas Configurator will help laser owners optimize their performance."

Huge welding auction in Seattle...but it's tomorrow...

2005-11-15T18:43:00.000-08:00

They have a ton of stuff on auction at the Seattle Shipyards tomorrow, Nov. 16. They have a 28 page PDF catalog listing more than 1,300 welding related items. You can download that from the auctioneers' page, here.

Some of it includes:

LODGE & SHIPLEY AVS engine lathe, 22" swing, 72" center distance, 3-jaw chuck, tool post, TRUE TRACE tracer attachment
LODGE & SHIPLEY engine lathe, 18" swing, 12' bed, collet chuck
LE BLOND engine lathe, 14" swing, 30" center distance, 3-jaw chuck, tool post, s/n: B11819
GRAZIANO SAG 17 lathe, 17" swing, 60" center distance, tool post, collet chuck
BULLARD 54" vertical turret lathe, SONY Magnascale X-Y digital readout
GISHOLT 4L turret lathe, 28" swing, 3-jaw chuck, s/n: 990-2
WARNER & SWASEY 1A turret lathe, 20" swing, tool post
BRIDGEPORT vertical milling machine, 9"x42" power feed table, 1 hp, s/n: 70759
LAGUN FTV-2S vertical milling machine, PATHFINDER X-Y digital readout, power feed table, s/n: SE3017A
ACER vertical milling machine, ANILAM X-Y digital readout, 9"x42" power feed table
BURGMASTER Econocenter NC milling/drilling machine, GE Mark Century controls, 39"x62" table
HERCULES radial arm drill, 8" column, 3' arm
METAL MUNCHER ironworker
SUNNEN MBB1600 hone, s/n: 43869
HARIG Super 618 surface grinder w/6"x18" mag chuck
PARKER hydraulic tube bender, s/n: 1652
DENISON 50 TON hydraulic press
WHEELABRATOR shot blast cabinet w/6' table
Sand blast system w/(4) hoses, storage system
TRINCO 36/BP sand blast cabinet w/dust collector, s/n: 45830-6
(4) horizontal band saws
AMROX 12 spd drill press
60' cutting & burning table, BURNY IV controls, (2) THERMAL ARC PAK 45 plasma cutters, 8'x40' plate capacity
(2) LINCOLN Idealarc 1000 welders
LINCOLN R3S800 welder
(3) LINDE 600 welders
(2) LINCOLN Idealarc DC600 welders
(26) LINCOLN R3R500 welders
(9) LINCOLN R3S400 welders
LINCOLN Idealarc 400 welder
MILLER Synchrowave 350 welder
(28) MILLER XMT 304 welders
(24) POWCON 300 SM welders
AIRCO 300 amp welder
MILLER 300 amp welder
MILLER CP200 welder
(2) AIRCO Pulse Arc welders
(2) WESTINGHOUSE welders
(7) MILLER Mk VIII 8 bank welders
BIRDSELL 8-bank welder
(5) MILLER XRA wire feeders
(30) MILLER S32P wire feeders
(10) LINCOLN LN25 wire feeders
QNW 650 CFM compressor w/ZURN air dryer
(4) SPEEDFLO airless paint pumps
GRACO airless paint pump
KREMLIN airless paint pump
(2) MTM 4000 psi portable water blasters
(8+) COFFING, CM 1-ton chain hoists w/jib
Assortment of chain hoists, lifting magnets, overhead cranes, welding equipment, welding leads, welding positioner, cutting tables, air hose, work benches, vises, machine vises, hand & power tools, pedestal grinders, SYNCHRO-LIFT boat lift, (3) 20'x45' portable sheds, 66'x96' steel shed w/bridge cranes, 50'x120' carpenter shop, 60'x120' steel shop building w/bridge cranes, other shipyard buildings, stores & supplies, too much more to list!

Friction Stir Welding - What's it mean to you?

2005-11-15T18:31:00.000-08:00

Friction stir welding, a process invented at Cambridge, involves the joining of metals without fusion or filler materials. It is used already in routine, as well as critical applications, for the joining of structural components made of aluminium and its alloys. Indeed, it has been convincingly demonstrated that the process results in strong and ductile joints, sometimes in systems which have proved difficult using conventional welding techniques. The process is most suitable for components which are flat and long (plates and sheets) but can be adapted for pipes, hollow sections and positional welding. The welds are created by the combined action of frictional heating and mechanical deformation due to a rotating tool. The maximum temperature reached is of the order of 0.8 of the melting temperature.

It's a manufacturing process welding type that really shows potential for things like building cars and other production items.

Wikipedia calls it the "Frictional heat is generated between the wear resistant welding tool shoulder and nib, and the material of the work-pieces. This heat, along with the heat generated by the mechanical mixing process and the adiabatic heat within the material, cause the stirred materials to soften without reaching the melting point (hence cited a solid-state process), allowing the traversing of the tool along the weld line in a a plasticised tubular shaft of metal. As the pin is moved in the direction of welding the leading face of the pin, assisted by a special pin profile, forces plasticised material to the back of the pin whilst applying a substantial forging force to consolidate the weld metal. The welding of the material is facilitated by severe plastic deformation in the solid state involving dynamic recrystallization of the base material."

Some places to check it out include...

The University of Cambridge, where it was invented, includes extensive explanations, photography, and video. Great site.
The Wikipedia is good, but brief. Not enough yet to sink your teeth into.

Welding curtains protect eyes, reduce debris, flashburns

2005-11-09T19:36:00.000-08:00

I've seen these used in a lot of shop environments, and think they work pretty well...

Welding curtains are an inexpensive way to segment off an area and keep it free of debris and dust from the welding area and sparks from everything else. The barrier material is available in many different configurations. It protects workers adjacent to welding operations from welding hazards like sparks, spatter, and ultraviolet light.

These barriers are free-standing sewn curtain panels, as strip curtains, or as bulk rolls of film or strip. Sewn curtain panels are offered with, or without a self-supporting frame. Screens with frame have optional casters. Strip curtain material is available in a bulk roll, with strip door hardware, as replacement strips, or with specialized hardware to build custom work stations.

Custom made welding caps

2005-10-29T19:48:00.000-07:00

I like to throw these things out when I see them. QuiltingB has a cool website with custom fitted skullcaps for welders. These welding caps are 100% pre-shrunk cotton & have a print fabric on the outside and are lined with a matching solid color cotton fabric.

The site says, "My caps are custom made to your head size. For your convenience." They offer a sizing chart.

Thinking of picking one up!

When to quit with a torch, and pick up a plasma cutter

2005-10-24T17:29:00.000-07:00

Oftentimes, welders are tempted into buying a plasma cutter to achieve better cutting results. Although that might be a good thing, it's not necessarily a have-to item. Here are some recommendtions before you take the plunge.

Before you quit torching, here are some things to check:
Be certain your regulators are high quality and in working condition.
Check for leaks in your gas plumbing. Use a drop of soap in water and an old paintbrush to help identify leaks.
Check your tip size. Is it correct?
Be sure gas tip pressures are set right for the tip you're using.
Preheat your tip right. Manufacturers sell tips in light, medium or heavy pre-heat settings. For clean steel use heavy tips. This can result in slag blow-through it you don't get it right.
Check your techniques and alter as needed. Are you holding the torch at the right position? Using it at the right distance? Be sure.

Get all that? Then buy you a plasma cutter if you think you can't live without it.

Rosie the Riveter was also Rosie the Welder

2005-10-22T13:00:00.000-07:00

In the dark days of World War 2, "Rosie the Riveter" became the famous nickname for a generation of women who took up industrial arts like metalworking, welding, and yeah, riveting, to keep industrial production up while the war went on. In many ways, we all owe them just like we do the guys carrying rifles in European plains and South Pacific jungles.

There's a website dedicated to keeping that memory, with a ton of good stuff at Rosie the Riveter.org. There are oral histories, facts, and other nifty stuff.

The Rosie the Riveter Memorial, honoring American Women's Labor During WWII, is the first national monument to celebrate and interpret women's crucial contributions to the World War Two Home Front. It is located in Richmond, CA, in Rosie the Riveter Memorial Park at the site of the former Kaiser Shipyards, which were the largest and most productive of World War II.

These days, a woman in welding is still a curiosity, something you might note and go on. Back in those days, it was revolutionary and vital. In certain places, such as California, plants could not have been run without them.

Here's to you, Rosie.

The top 10 Mig Welding Mistakes...

2005-10-21T19:03:00.000-07:00

Just a list compiled by various welders over the last few years.

Not cleaning your parts is the most common mistake in welding. Keep the metal in as perfect shape as you can get it.
Not understanding travel speed, the travel speed of your hand as you move. When you’re welding, stick out, or the distance that the electrode is allowed to stick out from the contact tip, along with travel speed are areas that a person has got to keep under control.
Improper gas selection. Cheaper gasses can cause problems. CO2 is going to be less expensive at the face of it, but might not do the job. Mixed gas usually gives better MIG welding results.
Mismatched filler material and metal. You must get the right tensile strength.
Inadequate shielding is another big mistake. Something as simple as not blocking the wind as you weld can cause huge issues.
Buying a welder that isn’t up to the job. People buy smaller welders thinking they are saving money, but it isn’t savings if you can’t do the job you need to.
Improper welder settings are a killer. You understand the settings and adjust them correctly. For instance, if your welder isn't set right, it will weld will lack fusion. It can look like a good weld, but isn't one. Using a light duty extension cord is a cause for this, as you can get a voltage drop. You'll have only half the output you thought you would.Your bead won't melt in, so it lacks fusion.
You must set polarity correctly - and many people don't. Setting your machine on the wrong polarity results in a really ugly weld. You can tell it’s wrong by the sound and how the welder isn’t flowing in your hands.
You have to maintain your wire feeder’s basic wear components. Liners, contact tips, and other parts wear out over time. Check your welder’s specs and replace them on time.
Wrong contact tip sizes. You can’t put a random contact tip on a MIG welder—it’s too critical of an element. Buy new ones as needed and size them right. Since the contact tip is where the electrical contact makes contact with the wire, it should be right. When a contact tip is burned back, don’t cut it off and try to keep welding. They aren’t that expensive and your wire will be sloppier if you tip isn’t set right.

Building a '33-34 Ford chassis from the ground up

2005-10-19T14:37:00.000-07:00

Nifty page on how this was done over at Custom Classic Trucks. Lots of good photos and documentation of the mig welding processes used to build this truck. A snippet (and I'm not including much since the original article is sensational and you owe yourself the time to go read it.):

After removing the center crossmember from the crossmember jig, Herb tack-welded and finish-welded the center crossmember into the framerails. Since the frame jig is a rotisserie, it can be positioned at any angle, enabling SAC's technicians to produce complete, uniform welds.

Robotic welding on the rise due to skills shortage

2005-10-18T17:10:00.000-07:00

According to the Ferret.com.au website, there is such a shortage of welding talent out there that it's driving more and more manufacturers to install automated welding machines. With better computer controls and more ability to automate, there are some formerly labor intensive welding jobs that are being moved into automation. If a company can replace a $50,000 a year welder with a $150,000 robot, they will do it because in 36 months (or less in the right) they'll have paid for that robot. The site reports that much of the conversion to automation is coming from the United States and Japan.

If it's not the right application, they'll have themselves a great coat rack, so companies have to be careful about this kind of conversion to automation

That robot won't call in sick unless they don't maintain it. It won't go on strike. It won't take two weeks of vacation a year or have health insurance.

Before you go thinking it's the end of the world for welders, relax. Rote, every day the same way jobs can be automated a hell of a lot easier than most welding jobs. Certain things, such as in repetitive manufacturing will go that way. But that's just the way of the world. I've been in grocery stores without any people to help me. I just check it out at the automated scanner. That's going to happen to those kind of repetive tasks whether they are welding or not.

Some snippets:

LONG production lines working 24 hours a day utilising robotic welders is a method of manufacturing normally associated with the automotive industry. But in fact robotic welding is being adopted by an increasing number of manufacturers, with most facing skills shortages and increasing labour costs.

“The other possibility is a smaller quantity of repeat items with each containing a significant amount of welding. In the end it’s all about having enough work to keep the robot welding all day, every day. Industries that are having difficulty in sourcing and keeping production welders may also benefit from robotic arc welding.”

“Converting to robotic welding really depends on the job and application,” he said. “Robotic welding combinations can start from $150,000 for a lower end robotic MIG welding system and ramp up from there depending upon welding technology required. However nothing extra is required beyond normal welding consumables except standard maintenance,” Deuchar said.

Marine welders example of Corps’ diversity, versatility

2005-10-12T14:42:00.000-07:00

From Marines.com

Every Marine is a trained rifleman, something the Corps takes a lot of pride in. However, in order to accomplish the Marine Corps’ mission, there are countless jobs that require Marines trained in many different military occupational specialties. A Marine Corps welder is one unique example.

Welders from General Support Maintenance Company, 3rd Materiel Readiness Battalion, 3rd Marine Logistics Group, flex their creative muscles for the Corps using skills learned in their formal MOS school and ingenuity that can only be learned on the job.

These welders can repair damaged Marine Corps gear such as vehicle parts as well as fabricate completely new parts, many of which can’t be purchased, at a fraction of what it would cost the Corps to purchase them through the civilian market.

“We can create or repair pretty much anything made of metal,” said Lance
Cpl. Alejandro Echevarria, a welder with GSM company, and an Austin, Texas, native.

Marine Corps welders attend the Basic Metal Workers Course at the Army Ordnance School, Aberdeen Proving Grounds, Md., There, students with exceptional talent can receive a certification from the American Welding Society. Once in the Fleet Marine Force, the welders can use their on-the-job training to apply for additional certification.

According to Sgt. Travis R. Nichols, the non-commissioned officer-in-charge of the weld shop and native of Hemet, Calif., a welder is like an artist. The skill level and patience needed for both professions is very similar.

Welders must be prepared to think outside of the box when jobs come in to optimize the capabilities of the Okinawa-based units they support.

According to Staff Sgt. Anthony L. Lashley, machine and weld shop staff noncommissioned officer in charge, one recent example that highlighted the type of fabrication work the welder Marines can perform saved the Corps thousands of dollars. A communications unit needed lids for cases to protect their equipment. The lids, available through order, were expensive and made of plastic. The weld shop fabricated metal lids for less than half the cost.

Welders must also have a vast knowledge of the materials they work with. They must know the best materials and procedures for making objects based on their structure and intended use.

“We have to be able to identify different types of metal and know what temperatures they fuse at by just looking at them,” Echevarria said.

The Marines of the weld shop take pride in their job and satisfaction from their work.

“It’s amazing when you make something out of nothing,” Echevarria said. “Seeing the finished product as something that was created by hand while saving the Marine Corps money is very rewarding.”

Welding data PDF's.. great sources of arc welding information

2005-10-11T18:23:00.000-07:00

Documents you can download for free with all kind of good welding information. You will need Adobe PDF reader to view them, but they're free.

Good stuff, especially the Army manual.

Fun with product labels...

2005-10-06T13:57:00.000-07:00

I picked this up browsing the web, and thought you'd think it was a hoot as well. A pair of "welding goggles" has a warning label that reads "DO NOT use these goggles for mig, tig, or arc welding".

Otherwise, I guess they're just peachy keen!

Warning: don't use these welding goggles for welding...

What are the job prospects for TIG welders?

2005-10-04T12:25:00.000-07:00

For Welding, Soldering, and Brazing Workers, the United States Department of Commerce thinks the future is pretty bright. According to its official website, "job prospects should be excellent." Lots of this is general stuff, but when they say that "Training ranges from a few weeks of school or on-the-job training for low-skilled positions to several years of combined school and on-the-job training for highly skilled jobs," they're saying that you get what you pay for. I think some guys do well in a self taught mode. They're just inclined toward the work. They're talented welders due to hand eye coordination, a good sense of how the metal is working, and steady demeanors. That doesn't mean you have to be born a welder. You can definitely learn it.

Commerce site goes on to say that about 55% of welders, solderers, and brazers work a 40-hour week, overtime is common, and some welders work up to 70 hours per week. Welders also may work in shifts as long as 12 hours. Some welders, solderers, brazers, and machine operators work in factories that operate around the clock, necessitating shift work. You and me both like the overtime, but not the lack of time after the whistle blows.

Welding, soldering, and brazing workers held about 452,000 jobs in 2002. Of these jobs, about 2 of every 3 were found in manufacturing. Jobs were concentrated in transportation equipment manufacturing (motor vehicle body and parts and ship and boat building), machinery manufacturing (agriculture, construction, and mining machinery), and architectural and structural metals manufacturing. Most jobs for welding, soldering, and brazing machine setters, operators, and tenders were found in the same manufacturing industries as skilled welding, soldering, and brazing workers.

Median hourly earnings of welders, cutters, solderers, and brazers were $14.02 in 2002. The middle 50 percent earned between $11.41 and $17.34. The lowest 10 percent had earnings of less than $9.41, while the top 10 percent earned over $21.79. The range of earnings of welders reflects the wide range of skill levels.

Ever had a flash burn?

2005-10-03T17:14:00.000-07:00

My high school welding instructor, who is long past this world now, used to describe them as "tater burns" on your eye. "You look at a live arc, I don't care how tough you think you are," he told us once, "and you'll be crying home to mama." I took him seriously and was happy never to get a flash burn, or welder's flash, as others call it. That paranoia has paid off for a while now -- to date I have never got one.

In a flash burn due to welder exposure, your corneas can get damaged by the ultraviolet light. It hurts, I'm told, a kind of subtle, always-there pain that takes 3 days to a week to go away. It takes about 6 or 8 hours to appear once you've been exposed. You can also get it from reflected light off water, snow, or even from sand. Long term damage is rare.

If it happens, the experts tell us to bathe eyes, both of em, with cold water. Lightly dress them with nonfluffy, clean materials (gauze would be good), and seek medical help if you aren't sure you've done it right.

Synonyms, Key Words, and Related Terms: actinic keratitis, snow blindness, flash burn, welder's flash, arc eye.

If you want the full scoop on welder's eye, read this article...

American Welding Society publishes Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding

2005-10-02T19:44:00.000-07:00

For those who follow the specification track, I like to throw these announcements out from the AWS...

Miami, FL September 9, 2005: The American Welding Society (AWS) announces the availability of: AWS A5.29/A5.29M:2005,Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding. This specification prescribes the requirements for classification of low-alloy steel electrodes for flux cored arc welding. The requirements include chemical composition and mechanical properties of the weld metal and certain usability characteristics. Optional, supplemental designators are also included for improved toughness and diffusible hydrogen. Additional requirements are included for standard sizes, marking, manufacturing, and packaging. A guide is appended to the specification as a source of information concerning the classification system employed and the intended use of low-alloy steel flux cored electrodes.

The American Welding Society is the largest organization in the world dedicated to advancing the science, technology, and application of welding and allied processes, including joining, brazing, soldering, cutting, and thermal spraying. Headquartered in Miami, Florida, USA, AWS serves almost 50,000 members in the United States and around the world. In 2005, the FABTECH INTERNATIONAL & AWS Welding Show—the largest welding, metal forming, & fabricating event—will take place November 13-November 16, 2005, in Chicago, IL, USA. www.aws.org/expo For more information on AWS programs and publications, visit the Society's web site, www.aws.org.

What if an autodarkening helmet fails?

2005-09-28T20:34:00.000-07:00

A usenet reader recently asked if he would be endangered if his autodarkening helmet failed. What would happen if the helmet didn't darken when the arc is started?

Well, first, it's not going to be the most comfortable thing to be exposed to live arc with the naked eye, but it is doubtful that happens.

The automatic shutter controls brightness, not the ultraviolet. Much of the UV screening for an autodarkening helmet is from the glass itself. When it darkens, that's to help a welder see better as much as it is to protect his eyes. Most helmets will fall dark when broken. The light filter offers some protection, as well. A quick glimpse of the arc is less trouble than a bare sight of the arc. Auto darkening filters are mechanically a bit stronger than the plain glass ones.

Ultimately, any autodarkening lens that meets the ANSI Z87.1-1989 standard--and most do--is the equivalent to a #14 filter for UV and Infrared even when it is off so you get dazzled but nothing more.

DELMIA Arc Welding enables the creation of robot arc welding process simulation

2005-09-24T22:21:00.000-07:00

More good stuff on automated tig welding, this time from Dassault Systemes. This basically means that designers can use 3D to plan and create arc welding robot programs while keeping hardware in production and in general not wasting time.

From their website...

DELMIA Arc Welding eliminates on-line production arc welding robot programming. Arc Welding allows the creation of arc welding trajectories and tasks in an offline environment and perform arc welding process optimization. This allows the user to plan and create arc welding programs while keeping hardware in production and minimizes mistakes and rework in arc welding robot cell development.

Seamless integration with Delmia's robot task definition allows users to create arc welding process specific task generation for development of a complete robot arc welding simulation with synchronization of all resources. The highly productive and intuitive simulation environment provides the tools required to fulfill robot arc welding simulation needs.

Orbimatic rolls out lightweight fusion tubesheet welding head

2005-09-21T16:19:00.000-07:00

I love the automated welding process stuff. Here's news from across the Atlantic.

Orbimatic Limited has released what the company describes as an innovation in the new P24 tubesheet welding head, an automatic TIG welding head designed for tube to tubesheet welding. It's used in high production environments where a fusion weld is suitable. Here's how it works: The weld head clamps directly to the tube to be welded via an expanding mandrel, which is operated by a simple mechanical clamping system. As the clamping mechanism clamps directly inside the tube being welded the head is automatically aligned concentrically.

The P24 is a fusion only Tube to Tube Sheet welding head which provides a cost effective solution for standard applications where a additional wire feed is not required. The P24 has a mechanical internal clamping system which locates the weld head on the tube to be welded which also provides concentric location. The welding cycle then runs from the press of a single button which is located conveniently on the weld head body. And as the weld head weighs only 1.4kg it is simple to use and move between welded joints.

The welding zone is fully enclosed during the welding cycle, which enables it to be used for highly reactive materials such as titanium. The base of the enclosure acts as a distance keep for the welding arc and eliminates the possibility of the tungsten coming to contact with the material being welded.

The P24 will accommodate tube diameters from 10mm to 26mm and has further flexibility, as it is possible to adjust the angle of the tungsten electrode. It can be used with any Orbimatic orbital welding power supply, which gives the world’s most advanced fusion tube to tube sheet welding system.

Check out the PDF brochure they have up on it here. See Orbimatic's UK homepage here.

Wisconsin machiner receives $40,000 state grant

2005-09-20T18:39:00.000-07:00

Fitchburg, Wis. - Jenkins Research and Manufacturing Corp. will receive $40,000 in state Technology Zone tax credits to expand its business, creating two jobs and retaining 25 more, Gov. Jim Doyle announced Tuesday.

Jenkins Research and Manufacturing Corp specializes in custom machining, welding, and fabrication of parts for the medical devices industry. They're investing nearly $400,000 to purchase equipment and increase production demands.

If you operate a machining, welding, or fabrication, there are times it's a great deal to get state or local seed money this way. Lots of states provide business assistance in training, consultation, or quality management as well -- typically for free.

New precision welding facility being constructed in Fort Wayne, Indiana

2005-09-18T07:34:00.000-07:00

Precision welding company Microtech Welding Corporation announced that it has broken ground on a new, 7,500 square-foot facility near Fort Wayne, Indiana, according to the Fort Wayne Journal Gazzette. The company performs precision microscopic and laser welding. In the Journal Gazette report, Robert Christman, Microtech’s president, described the new building as “an exciting next step in this company’s growth.” The welding company, which employs seven at its current location, serves customers that include the biomedical manufacturing industry.

No word on how many new jobs the expansion will result in. Precision welding is a skill some of you might be interested in looking into. If you're in the area, check it out. I can't find a URL for the company, but I would imagine that they would be easy enough to look up if you're in Indiana.

More welding safety options...

2005-09-17T11:11:00.000-07:00

Really, it can be inexpensive to make your welding operation safer, whether or not you're a home hobbyist, running a fabrication shop, doing outdoor pipe welding, or in an auto body shop. Some of them are the simple things -- common sense stuff you'll find in the welding safety area. Others are things you can easily buy, wear, or install around your welding area.

Screens can filter harmful light and eliminate the risks of flying sparks. I like Goff's curtain wall screens, myself.

In September 2001, The American Welding Society published safety standards including Lens Shade Selector, Specification for Use and Performance of Transparent Welding Curtains and Screens, and Ventilation Guide for Weld Fume. That is available for a nominal fee from the AWS website, so you might want to check it out before you purchase.

These ANSI-approved documents are for welding professionals to let us know about risks and hazards (and safety measures) for the welding workplace. Its lens shade chart uses electrode sizes, arc currents and more to prescribe comfort lens shades for welding and cutting processes. The specification for welding curtains and screens suggests safety equipment for outside viewing of the welding floor. The weld fume guide recommends ventilation systems to control welding fumes and cut energy costs in different weld shops.

Leather Welding Clothing & Safety

2005-09-16T20:19:00.000-07:00

The two types of materials most commonly used in welder protective apparel are chrome tanned leather and specially treated flame-resistant cotton. Today, let's focus on leather protective apparel for welders. Leather overgarments and gloves are best at resisting heat and sparks. Chrome-tanned leather works better than leather tanned by other methods.

Note: Photo from www.northerntool.com.

Leather is durable and will last several years if dry cleaned regularly after the garment becomes noticeably stiffened from accumulated dirt and grime. It's also heavy and hot, making working in it more difficult -- if safer -- than cotton clothing, even treated cotton.

Chrome-tanned leather, invented in 1858, is tanned using chromium sulfate and other salts of chromium. It is more supple and stretchier than vegetable-tanned leather, and does not discolor or lose shape as drastically in water as vegetable-tanned. Protective clothing should not be considered as a replacement for engineering control methods Since the clothing is the last line of defense for skin protection, care must be taken to ensure it provides the protection expected.

What can you wear in terms of protective leather welding clothing?

Gloves: Chrome tanned gloves tend to be supple and soft, allowing easy finger movement while resisting heat, sparks, slags, and cuts. Get a good pair. The last thing to skimp on is gloves. Your hands have to be able to move well, but also have to be protected. Gloves should be flexible as well as protecting you from heat.

Jackets & coveralls: leather welding jackets are heavy things, but if something goes wrong, you'll be happy you wore it. For heavy-duty protection there isn't much that's better for your torso and stomach. Look for larger, Kevlar stitches, heavy rivets, and plenty of versatile pockets. Should have closable snaps at sleeves, collars. The downside? A typical leather jacket weighs 6 pounds, which feels a hell of a lot heavier when you're welding.

Aprons: Can supplement your other clothing.

Spats: protect your boot tops by protecting them from sparks and slag.

Bib screens are great because they attach to the back of hard hats to shield your hair. Since sparks can fly up to thirty feet, you need to be aware that welding going on behind you can be as dangerous to you as welding you're doing on your own. Hoods cover your entire head.

Mazak to demonstrate live laser cutting at Fabtech 2005

2005-09-14T15:53:00.000-07:00

Hey there,

If you're going to the Fabtech 2005 show in November, here's something you might want to check out: Mazak Optronics is rolling out its Mazak FG Cad/Cam software in live presentations . They're calling it a real time software theater. FG CAD/CAM is used for multi-axis fabrication on Mazak's FabriGear and Space Gear lasers. If you're really into high end fabrication, you can control the cuts and save the ones you use most often, or even create NC programs on a computer and increase laser efficiency. The software can perform cutting simulations on the PC, so pre-cut interference checks can be run without tying the laser up.

Really cool: you'll be able program a pipe part then see it cut right there on a 3D rotary laser. The company will be at Booth #11024. Check Mazak's website for details.

Fabtech International & AWS Welding Show combined into the largest event in the world for metal forming, fabricating, tube, pipe, and welding equipment and technology. You have to catch it at McCormick Place South in Chicago, November 13-16, 2005.

New P450 Automatic Welding Machine Promises Increased Productivity

2005-09-13T17:02:00.000-07:00

CRC-Evans Automatic Welding is making noise on the rollout its new P450 Automatic Welding Machine.

According to the company, The P450 gives higher productivity on projects previously limited to standard welding machines. Such projects include those less than 50 km, with the necessity of supporting both GMAW and Pulsed-GMAW, and diameters less than 16 inches, CRA, and other exotic materials, and with the flexibility of handling both 2G and 5G welding.

Higher levels of productivity can be had because CRC-Evans designed the P450 with tandem welding capabilities – an innovation in which two welding wires are fed through a single head to increase deposition rates and welding speeds.

For details, see the CRC-Evans Automatic Welding Site.

Diamond Ground Products offers free guidebook, "How to correctly grind, cut & prepare tungsten welding electrodes"

2005-09-12T14:29:00.000-07:00

When welding companies release a nice guide or other item, I'm all over it. If you see one, contact us and we'll throw it online. Kudos to Diamond Ground for doing this.

Diamond Ground Products, Inc. has a nice freebie on its site you might want to get a look at: a Guide to selecting and prepping one of the most frequently overlooked pieces of the welding process: The Electrode.

You can spend big bucks on the right welding equipment, torches, power units and other stuf, but if you don't select and prepare your electrodes correctly, this less expensive process component can sabotage your welding results -- you'll have quality and consistency issues. According to Diamond Ground, this guide will help eliminate this variable as a concern in your welding and make it an asset.

The guidebook helps you select the most appropriate tungsten material and emphasizes the importance of a correctly prepared, ground and cut tungsten electrode. Other stuff includes safety issues surrounding the use of Thoriated Tungsten, and alternatives to this common yet radioactive tungsten material.

See Diamond Ground's Downloads Area for more information, or open the PDF file directly by clicking here: Tungsten Electrodes for Arc Welding.

How to deal with sticky weld slag on 7018 or 7014...

2005-09-11T09:53:00.000-07:00

I'm going to start highlighting discussions from Google's welding discussion group once in a while. If you're a welder and you aren't involved in it, I'd suggest at least reading it. There is tons to learn. I lurk, myself. This topic was a good discussion: "Really, really sticky slag on 7018 or 7014?"

This question was posed: "Is it generally true that when slag adheres MUCH more tightly than usual on 7018 or even 7014 that your amps are too high?" Answers included:

"It means your amps are too low."

"... it can happen with either to low or to much current. What makes slag stick is to have crevices. If you run to much current there will be undercut for slag to enter. If you run too little then there will be a crevice each side of the weld--and a place for slag to stick. A smooth flowing weld on each side without under cut helps prevent the slag. The main instance that I have trouble getting rid of 7018 slag is when welding in a deep groove that doesn't have enough slope on each side. This traps the slag making it nearly impossible to get out without anair chisel. "

"A highly crowned bead in a groove creates problems. The solution in that case is to make flat beads. Be motivated on this because you can't chip and scrape alongside your bead enough to prevent problems with the next weld."

"I've had more problems with slag sticking with low amps than high amps."

"As soon as I slowed down and let the puddle fill, the slag sticking problem vanished."

Consensus seems to be that low amperage and undercut are the problems with nasty, sticky slag. Will follow this one as it progresses.

Today,,,

2005-09-11T09:30:00.000-07:00

Hold your hand over your heart and remember 2001. It's still a fresh wound for many of us. I can't think of the firemen who entered the North tower, their chaplain giving them last rites even as they did, without shedding a tear. There was one more they might save, so they went. Same with the passengers of flight 193 who decided it would be better to die fighting the bastards (and saving a bunch of lives on the ground) than it would be to die in their seats. Heroes, all of them.

The lives lost are still with us. Here's to all of you. You deserved better.

Killer welding helmets

2005-09-10T21:10:00.000-07:00

Sometimes, you gotta marvel at the creativity guys put into their helmets. I've seen crudely hand-painted hoods, helmets with stickers, and a ton of other innovative stuff. I've also seen stick in the mud employers who don't allow any customization.

I've seen a billion variations of flames, skulls, flags, sports teams, fake scars & bandages, even people and cartoon characters. One of the cooler ones I've seen of late is a combination American flag/flames helmet at www.helmetguy.com. He also does hats, construction helmets, and other stuff you might like.

Custom Roadster Debut Kicks Off Miller's Dream Weldshop Sweepstakes - Make Sure you get entered...

2005-09-09T16:36:00.000-07:00

Custom Roadster Debut Kicks Off Miller's Dream Weldshop Sweepstakes. I'm taking this from PRNewswire via Yahoo, so go there for details.

The press release reads: "As much art as machine, Miller Electric Mfg. Co.'s custom high-powered '29 Roadster, which premiered last month at the 36th Annual Street Rod Nationals, was the subject of this week's TLC's RIDES program. The Miller Roadster's debut coincides with the announcement of Miller's Dream Weldshop sweepstakes, a celebration of the do- it-yourself welder."

The sweepstakes winner receives a welding and cutting package that includes the same models of Miller equipment used to create the hot rod, plus two hours of individual instruction from a Miller expert, a heavy duty welding table, auto darkening helmet and numerous other prizes. The Dream Weldshop package is valued at more than $12,000.

The Dream Weldshop sweepstakes runs from September 1 to November 30. Entry and contest information can be found on Miller's Website at http://www.MillerWelds.com .

Welders still in demand...

2005-09-08T19:10:00.000-07:00

Monotech/PSP Industries is expanding its operations in this Northeast Mississippi county. The expansion is expected to create 100 new jobs according to a Mississipi Business Journal report. General manager Greg Venatta said that the jobs would service a TVA account.

Most of the new positions are welders and fitters. Monotech/PSP said it is committed to hiring Gulf Coast evacuees, and those with welding or fitting experience are welcome to apply.

Monotech/PSP currently employs 200 workers in approximately 400,000 square feet of industrial buildings near Yellow Creek Port north of Iuka.

This is a good thing for some people who can definitely use a break. I don't have a web link to the company's site, but if you're in the area, and you're interested, youcan apply for employment with the company at its location on Mississippi Highway 25 North at County Road 342 or at the local employment office.

So, you want to be an underwater welder?

2005-09-06T16:39:00.000-07:00

I'm always amazed by people who can do the job. Diving is hard enough. Welding (skilled welding, that is), is hard enough. Combine them, and you have a mixture not quite like chocolate and peanut butter.

Yet, the need is undeniable and the pay is reportedly sensational. Given all the work to Gulf coast infrastructure that will have to be done over the next few years, I'll bet that employment opportunities are plentiful. So how do you get started? There are good schools and commercial diving institutions, which you can get a list of at Trade-schools.net. Another good source can be
the list of U.S. commercial diving schools accredited by the Association of Commercial Diving Educators can be obtained by contacting the Association of Diving Contractor, 2611 FM 1960 W., Suite F204, Houston, TX 77068; (713) 893-8388; FAX (713) 893-5118.

The American Welding Society has a good article here, which I'll summarize for you:

"By description, an experienced welder-diver must possess: commercial diving skills (i.e., be familiar with the use of specialized commercial diving equipment, have an understanding of diving physiology, diving safety, rigging, the underwater environment, communication, etc.); weld setup and preparation skills (i.e., the ability to perform tasks typically assigned to a fitter or rigger, such as materials alignment and materials preparation including beveling, stripping of concrete, fitting a steel patch or repair plate, etc.,); and the ability to certify to a required underwater weld procedure."

There aren't any age requirements for commercial diver welders, but it's a tough physical job. You'll want to check yourself out physically to even train it.

They go on to say, "Before performing on-the-job underwater welding, most diving contractors will require that you achieve sufficient skill in wet and/or dry underwater welding to pass qualification tests and be certified in accordance with the requirements of ANSI/AWS D3.6, Specification for Underwater Welding."

More welding companies rush to build generators

2005-09-04T18:56:00.000-07:00

Taking this directly off PRWire, but if it helps anyone, I hope they'll forgive me...

Miller Electric Mfg. Co. today announced that it is shipping additional emergency power generators to theGulf Coast region. This action is in response to the increased demand. They will be available at local welding supply stores, a source many consumers overlookwhen shopping for generators. To find a store with welding generators, call 800-426-4553 or visit http://MillerWelds.com.

Like common stand-alone generators, welding generators are powered bysmall gasoline engines and have regular 115V and 230V electrical outlets. Usedby contractors, farmers/ranchers, maintenance personnel, homeowners andmetalworking artists for welding, they also provide 4,500 to 10,000 watts ofpower for running tools, lights and appliances. Prices are comparable to, orless than, regular generators of similar quality and power.

Manufacturers cranking out generators

2005-09-02T17:01:00.000-07:00

In Minnesota, Coleman Powermate is cranking out generators as quickly as it can in the wake of the Gulf Coast devastation. One of the things most desperately needed there is the kind of generators that welding processes use. Coleman is going to longer shifts and adding workers to help bring temporary power to victims and rescue workers.

If you're in Springfield, MN or the surrounding area, and you're looking for work, you could do worse than to help them out. They're adding welders assemblers, metal fabricators and others to meet the demand. They are running 22 hours a day to attempt to double generator production. Every truckload is heading South to help, according to the company.

They build 5,000 and 6,000-watt generators -- enough to run household appliances, emergency lights, and other needs. Their generators page can be found at http://www.colemanpowermate.com/powerstation/

Airbus to Implement Friction Stir Welding?

2005-08-30T18:18:00.000-07:00

Speednews is reporting that Airbus will become the first big-airplane manufacturer to adopt friction stir welding production. The friction stir technique welds aluminum without melting it and eliminates the need for rivets. Airbus said it was planning on using friction stir welding on A350 assembly. This is a cool method for joining metals.

If you're into the technology side, check out The TWI World Centre for Materials Joining Technology site. Tons of links there.

Quick summation here:

In friction stir welding, a cylindrical, shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two butted-together pieces of sheet or plate material. The parts have to be clamped onto a backing bar in a manner that prevents the abutting joint faces from being forced apart. Frictional heat is generated between the wear resistant welding tool and the material of the workpieces. This heat causes the latter to soften without reaching the melting point and allows traversing of the tool along the weld line. The plasticised material is transferred from the leading edge of the tool to the trailing edge of the tool probe and is forged by the intimate contact of the tool shoulder and the pin profile. It leaves a solid phase bond between the two pieces. The process can be regarded as a solid phase keyhole welding technique since a hole to accommodate the probe is generated, then filled during the welding sequence.

Katrina, the Gulf Coast, and New Orleans...

2005-08-30T18:06:00.000-07:00

During the last hurricane, there were news stories about welders and welding distributors donating generators to help with the situation. What they're facing in Missisipi, Louisiana and Alabama is such an unspeakable disaster that I don't think anyone knows how to proceed yet. It's one of those problems so huge that you can't start to get your mind around it-- any step seems pointless given the destruction.

Yet, a few generators can maybe make a positive difference for some people. Welders were generous for Andrew. Let's hope we can be so for this unimaginable disaster.

Speaking of that, Northern Tool has established a hotline for generator users during hurrican season. For those who might need assistance on their generators, it's a good place to start. Call (800) 214-8921 toll-free if you need it.

American Welding Society introduces Certified Welding Supervisor Program

2005-08-28T19:55:00.000-07:00

Claiming that it will reduce welding costs and increase profitability, the American Welding Society rolls out its Certified Welding Supervisor Program. The program is designed to give managers, engineers designers and foremen the ability to enhance profitability and reduce welding costs. I don't know if anyone's interested in it, but for the right company, it might be a good thing.

Just for the fact that it gives you a consolidated body of information to draw from, I'd think it would be interesting to get involved with. I agree with the AWS that too often managers and supervisors are too ignorant of welding processes and procedures, and that if they can bring up that knowledge base, it's good for everyone in the business.

Check all of out AWS's certs programs here: http://www.aws.org/certification. They have tons. The Supervisor certification can be found at http://www.aws.org/certification/CWS.

Valley National Gases buying Reynolds welding supply...

2005-08-25T16:40:00.000-07:00

A bit of welding business related news here...these guys are acquiring quite a collection of welding companies.

From PRWIRE: Valley National Gases Incorporated today announced that it entered into a formal agreement to acquire Reynolds Welding Supply Company, Inc. and its subsidiaries, Welders Supply Company, Inc. and Twin City Oxygen Company, Inc. The Companies are industrial gases and welding supply distributors, with a total of six operating locations, five in South Central Minnesota and one in Southeastern South Dakota. Aggregate annual sales, for all three companies, is approximately $20 million. Valley National Gases' Vice Chairman and Chief Executive Officer William A. Indelicato commented, "We are pleased to have the associates of Reynolds Welding, Welder's Supply and Twin City Oxygen join our Valley family. The Reynolds Companies provide us with the opportunity to participate, with a strong presence, in the states of Minnesota and South Dakota. Although these businesses are not contiguous with Valley's current operations, we believe the size and quality of all three companies provide us with an excellent new base of operations in the upper Midwest."

Portsmouth taken off base closing list

2005-08-25T14:33:00.000-07:00

Just a quickie update - the welders and other guys at Portsmouth can breathe a sigh of relief. They were removed from the Pentagon's base closure list. Other sites are on the line, and other welding guys are on the line as well. More on this later...

BRAC votes today - 600 bases at stake...

2005-08-24T05:05:00.000-07:00

Just a quick follow up to yesterday's post on the welders at Portsmouth Naval Shipyard and its peril due to the base closings process. Today's the day the BRAC votes for final recommendations that'll be sent to the President. My guess? The initial bases will all be closed. That's been the history of base closings. It's a brutal thing, and all these guys deserve better, but we can't keep bases we don't need.

Keep an eye open, and think good things if you're at one of the affected facilities.

Pipe Pal - a nifty pipe welding template

2005-08-20T08:00:00.000-07:00

I ran across The "Pipe Pal" the other day and thought some of you pipe welders might be interested in what appears to be a good pipe template. It works by aligning saddles and 45 degree pipe ends for easy marking. They sell em' in 2" and 2-1/2" diameters. Looks like it'd make a piping, fencing, or handrail job go quicker and match better.

I haven't used one yet, but I'll review it once I have.

American welding society releases ANSI Z49.1:2005 Revision

2005-08-19T15:32:00.000-07:00

The ANSI Z49.1:2005 Revision is now available for free download from the American Welding Society. I'll throw out their press release so you can find it if you're so inclined.

FOR IMMEDIATE RELEASE (See it over at AWS's site)

Miami, FL-August 17, 2005: The American Welding Society's (AWS) Board of Directors recently authorized free electronic distribution of the current (2005) revision of ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes.

The Board decided this important voluntary welding safety and health standards document should receive the widest distribution possible and has directed that Z49.1-2005 be made available for free download from the AWS Website http://www.aws.org/technical/facts.

During World War II, the huge demand for war materials production placed on the United States brought a tremendous expansion in the use of welding. In mid-1943 it was recognized that some type of code or standard was needed relating to safe practices for performing welding. Under the auspices of the American Standards Association, the standard was drafted and published in 1944. It was entitled American War Standard Z49.1, Safety in Electric and Gas Welding, and Cutting Operations.

Following the war, the standard was first revised in 1950. Subsequent revisions occurred in 1958, 1967, 1973, 1983, 1988, 1994, and 1999. During the period of these revisions, the American Standards Association has become the American National Standards Institute and War Standard ASA Z49.1-1944 became ANSI Z49.1-2005.

Chip Foose chooses Lincoln Electric as welding source

2005-08-17T15:47:00.000-07:00

This is press release fodder, but Foose's choice of Lincoln products will be good marketing for them and probably help their efforts...

"Provocative designs and sleek curves are the hallmarks of legendary hot rod designer and fabricator Chip Foose. His work has already captured three Don Ridler Memorial Awards, one of the most coveted trophies on the show car circuit. As the lead designer and builder of the Discovery Channel series Overhaulin' that airs weekly on TLC, Foose is a household name among those who tune in to see how he and his team of technicians radically transform a car for its unsuspecting owner. Viewers of the show are also familiar with Foose Design, his Huntington Beach, Calif., shop, equipped with only the best tools to translate design ideas into reality.

Recently, after a side-by-side comparison, Foose replaced his former brand of welding equipment to outfit his shop solely with Lincoln Electric MIG, TIG and plasma equipment. Citing a better arc and improved welding performance, Foose and his fabricators are now taking advantage of the Lincoln Power MIG(TM) 350MP and Power MIG 255 MIG welders, Precision(TM) TIG 275 and Invertec® V205-T TIG welders and Pro-Cut® 55 plasma cutter.

"I love Lincoln's Precision TIG with Micro-Start(TM) because you can get right in there and see what you're working on before you start melting the metal," said Foose. "It has a much lower heat input, which gives you more control and just an overall beautiful weld. All of our craftsmen love them. Our Lincoln plasma cutter is great too. You can get into tight places with no problem."

Read the rest over at Yahoo...

A site I recommend on welding history

2005-08-15T17:20:00.000-07:00

Just a quick link for you here on welding history. Even the wikipedia doesn't have the depth that Mark Sapp has put together for his website, weldinghistory.org. It's got the roots of welding from as early as 6000 B.C. and stretching to modern times. Fascinating stuff, if you're a welder or otherwise interested in metalworking.

Design News details Titanium welding advances

2005-08-15T16:34:00.000-07:00

One of my favorite sites is Design News, so when they have something about welding, I always make a point to give it a shout-out. This time they're going in depth about a highly anticipated welding code to help engineers and increase titanium use in industrial and military areas. That code, the D1.9 Structural Welding Code for Titanium seems to be on its way toward final approval.

The code's in its ninth stage of revision, and was submitted to the American Welding Society for approval in May 2005. According to the AWS website, it's going to be approved by mid-2006.

Herrmann Ultrasonics unveils FDA compliant ultrasonic welder

2005-08-14T06:03:00.000-07:00

I don't normally get into plastics welding, but it is a part of this business so I thought I'd cover it. It's an expanding field and very different from the metalworking, but still related.

In Schaumburg IL, Herrmann Ultrasonics has unveiled the first (and they say only) FDA-compliant ultrasonic welder. The FDA System is an add-on software package. It meets FDA CFR 21 part 11 standards for login and traceability.

Login in screens let only authorized personnel operate the system. Operators can be defined as an Administrator, Supervisor, Setup, or User(s) and can be enabled or prohibited from changing the different features of the DIALOG touch weld process controller. An Audit Trail (electronic record) is created, showing all changes made and the user that made the changes (electronic signatures).

Herrmann Ultrasonics has been setting industry standards with features such as true Windows®-based touch screen controllers, most rigid machine design, built in calibration, and on-screen weld process graphing capabilities. The FSC software continues the pioneering path of the recognized technology leader in ultrasonic welding.

Read the details over at the Herrmann Ultrasonics website...

Monster Garage: "How to Weld Damn Near Anything" Book

2005-08-03T15:41:00.000-07:00

Monster Garage's "How to Weld Anything" Book

This one has been out for a while, and I think it's okay. There are probably better books out there , but this one has that golden brand name. If you're a Monster fan, you may want it for collection purposes. If you're starting to learn to weld, it has some good stuff. But there might be better resources out there, depending on your expertise and situation.

The publisher has this to say: "Want to learn how to weld just like they do on Monster Garage? This invaluable guide to welding covers techniques used for Indy and NASCAR race cars, experimental aircraft, and other applications requiring high-quality welds, including welding 4130 steel, stainless and aluminum, as well as plasma cutting. Learn how to select equipment, set up your welding shop, pre-weld jigging and fitting, and how to choose the right process and fill metal for each project. Includes chapters on the latest technology in filler metals and welding rod."

Give it a look. They have a neat feature that lets you preview pages, so you can get a peek inside.

In Southern California, Welders File Mass Tort Lawsuits

2005-08-02T15:23:00.000-07:00

It's heating up on the mass torts front for welders and welding rod fume exposure. I don't know how to interpret this yet. We do need to know how much potential harm there is out there for welders when we are exposed to these fumes.

Yet, part of me has seen the explosion of lawsuits -- especially class action stuff where only the lawyers seem to win -- and wonder about the situation. (Ever read John Grisham's "The King of Torts"? It'll make you wonder.)

According to BusinessWire, 8 Southern California Welders File Mass Tort Lawsuits Against Airco Inc., Caterpillar, Inc., General Electric Company Among More Than 55 Defendants for Injuries Caused by Exposure to Welding Fumes.

Eighteen welding rod workers filed a mass tort lawsuit today in Los Angeles Superior Court against Airco Inc., Caterpillar, Inc., General Electric Company and more than 55 other named defendants claiming that they suffered serious neurological injuries as a consequence of exposure to welding fumes containing manganese, a substance medically recognized as toxic to the human central nervous system. Plaintiffs' complaints for damages allege 15 claims, including negligence, strict products liability, and fraud/deceit by suppression/concealment, involving welding products that were manufactured, sold, distributed, and/or promoted by Defendants. All of the Defendants were, at relevant times, manufacturers and sellers of welding products, large industrial consumers of welding rod products, and members of leading trade organizations, including the American Welding Society and the National Electrical Manufacturers Association.

The Plaintiffs are jointly represented by the Santa Monica, CA law firm of Greene Broillet & Wheeler (Bruce C. Fishelman, Timothy J. Wheeler, Geoffrey S. Wells), the Los Angeles, CA law firm of Panish, Shea & Boyle, LLP (Brian J. Panish, Kevin R. Boyle), the Los Angeles office of Kirk B. Bernard, and the San Francisco, CA law firm of Lieff, Cabraser, Heimann & Bernstein, LLP (Robert J. Nelson, Eric B. Fastiff). John John vs. A.O. Smith Corporation, et. al., Case No. BC337178.

I'll keep an eye out on this...

Austin, Texas welder sparks career as steel works artist

2005-08-01T18:09:00.000-07:00

Central Texas is filled with wonderful artists. And while each has followed a unique path, Jimmy Harwell, a Hays County artist, got a late start at it -- entirely by accident.

"Of course we had horses and rode a lot and so I always wore spurs," Harwell said of his childhood. "But you know always wore real cheap spurs, then I decided 'well I'll just make some spurs,' and actually I made my first pair when I was 17."

And so began Harwell's artistic career. He just didn't know it at the time.

Eventually, this welder by trade started making the decorative kind of spurs and many other works. His art career officially started decades after those first spurs while enrolled at Austin Community College.

See the rest at Austin's News 8 Website...

Sand Shark mechanics keep Al Taqaddum’s engines running

2005-07-25T14:29:00.000-07:00

Here again, we can prove that some welding jobs are just more important than others. Ever complain about where you're working, what you're doing? I bet these welders are in a harder place, doing a thankless job, to little thanks. They're putting it on the line, and helping make sure more Americans come home alive....

From providing rescue and firefighting to fuel delivery services, the Sand Sharks of Marine Wing Support Squadron 371 have multiple tasks while deployed in support of Operation Iraqi Freedom. One of the most important ones is vehicle maintenance.

“Every mission out here requires vehicles,” said Lance Cpl. Joshua Deblasis, a mechanic and Cleveland native. “We contribute to every operation by fixing vehicles for anyone on base, keeping everyone combat ready.”

The mechanics and welders in the platoon work with a common purpose, to repair Sand Shark vehicles and help any other unit that needs assistance.

Read the entire article over at Military Family Network.

Welders are in demand—how can you ramp up your income?

2005-07-24T17:15:00.000-07:00

This morning I opened my local paper to a Business section front-page story about the local and nationwide shortage of skilled welders. One local company said they’d add 30 to 50 more welders if only they could find them. There were plenty of other businesses complaining about the lack of qualified welders.

That’s here in Tulsa, with a world-class welding school, Tulsa Welding School, right in town pumping out welders every year. I can imagine it’s even worse for metal working and manufacturing companies in places without a large welding school.

Does this mean that you can automatically demand more money? No, of course not. But it’s always good to be in a business when there is a shortage of what you do for a living. Ask any nurse over the last few years. They’ll throw money at the right person, but they’ll work you a lot of hours.

So what can you do?

If you have a job, it might not hurt to look around for another one. Look, if you’re in a situation you like with a company you want to work for doing what you want to do, there isn’t necessarily a reason to leave. But if you’re good, and your company values you, there is no reason to not talk about money with them. There also isn’t any reason not to keep your eyes open for a welding job you’ll like better.

If you’re not in a situation you like, what are you waiting for? You’re in the catbird seat. They need you out there if you can handle a welder, if you’re on time and give them a good day’s work.

Get what you’re worth, get a job you don’t mind getting up in the morning to go to.

Arizona Western College offers Welder's Certification Class

2005-07-21T15:52:00.000-07:00

Phoenix-area welders wanting to obtain skills education for passage of the American Welding Society code can participate in AWC’s (Arizona Western College) next Welder certification class, starting in August.

The 2-credit course meets Wednesday mornings from 8 a.m. to 8:50 a.m. A lab is held from 9 a.m. to 10:40 a.m.

There is $65 fee for the course in addition to the tuition and textbook. Students will receive specific instructions on materials preparation, electrode selection and application for testing to the AWS D1.1 structural welding code for certification as an all-position certified plate welder using low hydrogen electrodes. Persons enrolled in this class should have already passed Welding 106 or have previous welder education. To receive their welding certification document at the end of the course, students will demonstrate proficiency in welding to this code before an independent welding inspector. Students can also participate in testing modules for passage of the AWS SENSE Level I certification. Successful candidates will be eligible to receive both the code certification card and the AWS SENSE certification.

Interested persons should register IMMEDIATELY for course number WLD-127-001 Welder Cert./Code App. For more information please contact Professor Colton by e-mail at samuel.colton@azwestern.edu or by phone beginning August 8.

Welding Suppliers Meet Demand for Generators in Hurricane Dennis' Wake

2005-07-18T16:52:00.000-07:00

Some good work being done by the welding industry in the wake of Hurricane Dennis. I hope this helps out anyone who needs it...

APPLETON, Wis., July 18 /PRNewswire/ -- Miller Electric Mfg. Co. today announced that emergency power generators continue to be available at welding supply stores, a source many consumers overlook. Hurricane Dennis left more than 680,000 people in four states without electricity. Utility companies estimate some will be without power for up to three weeks. To find a store with welding generators, call 1-800-426-4553 or visit MillerWelds.com.

Like common stand-alone generators, welding generators are powered by small gasoline engines and have regular 115V and 230V electrical outlets. Used by contractors, farmers/ranchers, maintenance personnel, homeowners and metalworking artists for welding, they also provide 4,500 to 10,000 watts of power for running tools, lights and appliances. Prices are comparable to, or less than, regular generators of similar quality and power.

More Devastation Predicted

"Having a Category 3 hurricane with 120 mph winds strike so early in the year should encourage people to be prepared for more power outages," said John Leisner, Miller product manager. "Even though generators may become scarce in retail stores, we have ensured a sufficient supply of welding generators in anticipation of another rough hurricane season."

Miller recommends considering power needs before purchasing a welding generator. Critical appliances to run during an emergency include well pumps (750 watts), sump pumps (800 watts), refrigerator (700 watts), air conditioners (2,500 watts) and radios (50 to 200). Note that many appliances take much more energy to start than to run. For information on running home appliances and tools, plus a power calculation worksheet and safety instructions, visit MillerWelds.com/products/generators.

TLC's "Rides" Features Lincoln Electric Welding Equipment

2005-07-15T18:36:00.000-07:00

Dontcha just love it when a television show does a fix-up for an already-wealthy celebrity?

Lincoln Precision(R) TIG 275 used for Fabrication Work on Joe Rogan's 1970 Barracuda

CLEVELAND, July 14 /PRNewswire/ -- You've seen Joe Rogan as the host of NBC's Fear Factor tempting contestants to eat insects or perform daring feats of physical endurance. On a recent episode of The Learning Channel's (TLC) Rides show, Rogan himself is the center of attention as his restored 1970 Plymouth Barracuda, called the Sick Fish, is unveiled to him for the very first time.

As part of the show, hot rod designer Chip Foose created the Sick Fish's new design, while Troy Trepanier and the team at Rad Rides by Troy performed the fabrication work on the car. A key piece of equipment used in the process was The Lincoln Electric Company's Precision TIG(TM) 275.

According to Dan Holohan, head fabricator at Rad Rides by Troy, consistency, reliability and ease of use were the primary reasons the Lincoln Precision TIG was chosen for this application. "The arc doesn't dance around at the start like some TIG machines. With the Precision TIG, the arc starts where you point it," said Holohan. "With its MicroStart(TM) Technology, the machine produces a stable, consistent arc that is very controllable. We always look for the best weld we can possibly produce, regardless of whether we will grind the weld or leave it exposed. With this machine, we know we are achieving high quality welds."

Read the rest (and envy Joe's car) here.

NIOSH Seminar Will Discuss Potential Health Effects of Welding

2005-07-08T19:36:00.000-07:00

There is an emerging concern within the occupational health community about the potential pulmonary and neurological health effects associated with welding fume exposure.

A seminar offered at West Virginia University in Morgantown, WV, HSC Hostler Auditorium will discuss these issues.

Welders are exposed to fumes that are comprised of metals, such as chromium, nickel, manganese, and iron, which have been observed to be toxic to the lungs and brain. Numerous queries dealing with this arising occupational health issue have been received by the National Institute for Occupational Safety and Health. The proposed conference will address and discuss all aspects welding fume exposure and health.

Following this conference, participants should be able to:

understand the various types of welding in order to recognize potential health hazards
describe the constituents and composition of welding fumes
describe the fate and behavior of substances inhaled from welding
discuss the known or suspected adverse pulmonary and neurological effects associated with welding exposures

Making Sure Steam Piping Is Safe - the role of welders

2005-07-06T16:01:00.000-07:00

Over at Parmaceutical Processing magazine, they've got a good article about keeping steam piping safe. Lots of welding tips in it - check it out. They call it "10 simple things that might keep you alive."

In Louisiana, Union Tank Car seeks welders for new plant

2005-07-03T13:54:00.000-07:00

If you're a welder in the Baton Rouge area, this one's for you...

The Louisiana Department of Labor and Union Tank Car Co. announced Friday that the employment process for job applicants for welder positions at UTC begins Tuesday, June 14. UTC is stressing that only welders are being recruited at this time. Other positions will be announced later.

The Chicago-based company Union Tank Car is building a railroad tank car manufacturing facility and expects to hire 850 workers for a variety of jobs once construction is completed in 2006. Applicants can apply on-line at the labor department Web site www.LAWORKS.net or at any of the department’s One-Stop offices, June 14 through June 30. The One-Stop addresses and phone numbers are listed on the labor department’s Web site.

In Wisconsin, Welding rod suits seek more than $30 million

2005-07-01T12:42:00.000-07:00

A huge series of suits in Wisonsin on welding rod suits. Read the rest at the Madison County Record website...

Music City Motorplex adds ARCA Lincoln Welders Truck Series to “Tennessee Stock Car Tripleheader”

2005-06-28T15:33:00.000-07:00

If you're a racing fan, this is fun news...

TOLEDO, Ohio -- Officials from the ARCA Lincoln Welders Truck Series have announced an addition to their 2005 season schedule.

The season will now run through the weekend of October 15 & 16, with the Music City Motorplex adding the ARCA Lincoln Welders Truck Series to the Tennessee Stock Car Tripleheader.

“We’ve been talking to (Music City Motorplex promoter) Joe Mattioli, and track GM Jack Deery for some time about an ARCA Lincoln Welders Truck Series race in Nashville,” commented ARCA VP for Competition Joe Wells. “Fortunately, we were able to find a mutually agreeable date for a truck race, fitting in nicely with their October 15-16 special event.”