Welder World Blog

Posts Tagged ‘quality’

Welding is a procedure that involves joining two materials together. It has been in usage right from the Bronze and the Iron ages. Over the years, welding has become much more than a mere forging process and today uses lasers and other gadgets to achieve the purpose of joining materials.

In today’s times welding no longer remains a profession that is chosen by unskilled people. It is a major profession as without welding, even routine equipments would become impossible to use. In fact, the profession has become so well-known that there is an entire university dedicated to teaching people about the various requirements of welding. The Hobart Institute of Welding Technology, based in Ohio, US was started in 1930 and still is the leading institute in terms of the career choice. The institute provides not just training but also teaches its students the aspect of safety while carrying out welding.

In terms of safety and carrying out the process of welding the primary requirement is that of the availability of good welding supplies. Welding is not a simple and easy process. It requires lots of primary inputs. One of the most important inputs is power. Welding is impossible without power to generate the welding. This is why welding generators are highly powered so that there is no time wasted while carrying out the process. The amount of power required to operate a welding machine is over 80 amps.

Other welding suppliesinclude welding pipes, welding positioners – to hold the equipment properly and the pipe bully. Pipe bully is mainly used to rotate the welding pipes so that the equipment does not slip and the welder does not encounter any loss to the welding material or to himself.

There are many companies that deal in distributing quality welding supplies. For example the pipe bully that is marketed by All-Fab Corporation. The Welding Supply Guide offers premium welding supplies to its clients based in the United States and Canada. In fact, in the United Kingdom there is a firm that provides welding supplies to its clients through the medium of internet so that both time and energy can be conserved.

With the help of the right welding supplies, welding professionals can ensure perfect delivery of the job carried out. Also considering the risk involved in the career, these professionals also end up ensuring safety of not just themselves but also of other people who might be around.

Metal inert gas welders are semi automatic and in some case, automatic welding processes used to weld cracks and tears on a metallic surface.  A continuous voltage and a direct current source of power is used along with an alternating current.

High quality MIG welders are up for sale during the season and some store even offer a whole lot of discounts and other bargains on the deals. It is a perfect time to buy mig welders during the season as one is also better informed of the latest technological developments in the sector. During the sale period, many companies, old and new display their latest models and educate the technicians and other buyers on the qualities of their latest offerings. Some companies even show extensive demonstrations on cars and other automobiles to prove their point. This is also the time where you can get you automobile repaired for free if you are buying a welder. This policy was started lately and has been popular ever since. In fact t has also boosted the sales of mig welders. Both the seller and buyer are happy and satisfied with the outcome. During the sale of such mig welders, workshops are held in various parts of the town to educate and enrich the knowledge of new and old technicians. It becomes the good platform for displaying one’s talent with the welding machine. There are also competitions for such purposes.

Mig welders are also sold online and have become a very popular method for the sale and purchase of these welders. The online welder vendors offer great discounts and the prices are competitively placed. You can also compare the prices and qualities of two mig welders of different or the same company on the website and make your decision in a well informed manner. Most online companies send you their advertisements via the email or even through personal cell phone messages and instant internet messaging. You can respond by clicking the websites they have listed in the email, message or advert pop up. You come to the landing page and from there onwards can look at the plethora of options provided to you by the company. You can look at all the models from all the possible angles and can enquire through live chat from the executives about the details of the model. After you have shown sufficient interest, you will be invited to look at the models and then can place your order either at that time or over the internet.

The goal of every organization is the continual improvement of its manufacturing processes. There is no exception for the arc welding industry. All would agree that information is at the heart of continuous improvement. Information is required to direct the very action necessary to improve processes or resolve problems. Without information, organizations employ random acts with unknown benefits. This wastes valuable time and resources.

Information in the welding industry includes a myriad of data; material data, consumable data, fixture tolerance, part tolerance, weld process information, and much more. Weld process information is a substantial and critical component to improving welding applications. A valuable AIDE would provide the necessary tools to analyze and optimize the weld process.

Intentional collection, storage, and analysis of weld process data has largely been avoided. Welding, for too long, has been solely considered an art at the expense of good engineering practices. The art of welding many times is at the center of an organizations setup, maintenance, and launch of welding applications. As a result, organizations tend to lack documentation, setup methods, and historical information. Procedures derived from information produce common launch practices, universal “best practice” weld procedures, expected productivity and utilization metrics, and historical analysis of preventive maintenance practices to name a few. In a report released by the U.S. Department of Energy Office of Industrial Technologies titled Welding Technology Road Map, the report stated “The transition of welding over the coming decade to a rigorous science based on physical data will contribute greatly to the industry’s success in achieving its vision.” Information is and will be increasingly more the cornerstone of improving and advancing weld practices.

A common opinion, which becomes a barrier, is information driven practices are for fortune 500 companies. That is sorely untrue. Large companies are highly dependent on medium and small suppliers to provide a myriad of components. It is obvious the overall assembly is only as good as the weakest link. Best practices must be employed throughout the chain. The benefits are huge; multiplied efficiencies, information sharing, common practices throughout the supply chain. Consider a mobile work force that can transition from industry to industry utilizing universal practices and tools similar to an electrical engineer employing data acquisition techniques to develop PC electronics and automotive electronics. The electrical engineer uses the same oscilloscope in each capacity. The electrical engineer requires the same information. This should be the same in welding. The welding professional will utilize a universal tool to capture the same information whether the application is a car frame or heavy industry tractor. Information will drive setup, maintenance and production activities.

A read of the industry suggests a new openness to embrace information and its effective utilization. In order to marshall in such an opportunity, a welding AIDE is proposed; a process independent method defining the steps for continuous improvement. AIDE is a simple acronym and easy to remember. It can be the building block to a successful practice to continually improve arc weld operations.

Step 1: Audit – gather real-time weld process information and store creating a historical database

Goal: Collect footprint of welding operations
Metrics: Machine utilization, productivity, Weld Signature® capture

Step 2: Identify – analyze welding information creating knowledge base

Goal: Document weld process and measure process stability and repeatability
Metrics: weld process set point, repeatability of a given weld, number of welds per part, reasons for downtime.

Step 3: Detect – establish control limits and alert on loss of process control

Goal: Bound weld process and alert when violated
Metrics: detect missing welds, detect incomplete welds, detect process anomalies

Step 4: Engineer – use weld information coupled with welding knowledge to improve

Goal: Exploit weld process data to increase quality and velocity
Metrics: tighter process operating range, reduced downtime, reduced process faults

AIDE is an iterative methodology which is continually implemented. Continuous improvement is by definition “continuous”. As such, the method requires a tool to automate the acquisition, analysis, and collection of weld process information. The AIDE methodology is only as good as a tool that makes it possible. What is interesting is the implementation and study of the AIDE methodology largely defines the necessary features of the tool. The tool must quickly and effectively source the information necessary to perform each AIDE step. The goal is continuous improvement and the tool is an enabler to that end.

Why has my MIG wire gone bad all of a sudden?

“I’ve been using this MIG wire for the last six months without a problem”. “Now after having used many spools the wire its gone bad”. “What’s happened?

Sound familiar? The trouble here is that the person or company that you bought your MIG wire from cannot guarantee you quality.

Did you buy the cheapest stuff you could find? Ha-ha…As the saying goes, “he who buys on price, and price only, gets what he paid for”.

Sounds harsh but that’s the truth. Quite often you find end users happily welding away with their current brand of MIG wire. When all of a sudden they go and open up the next new pallet of wire that just arrived, slap it on the machine and the welds are all over the place.

Spatter, burn backs wire not feeding properly and so. What’s going on, they think to themselves. “Ahh, I know, it must be a worn contact tip”. So off they go and replace the contact tip with a new one. But no, sure enough same problem. “Well, it’s been a while since I change the liner”. So off they go and do that. Yet sure enough the same problem is still there.

They think to themselves, “well I’ve changes everything else, it can’t be the wire. It’s brand new and I’ve been using it for over six months without any trouble”.

This is such a common thing to come across in the welding industry, and it affects everyone throughout the world. Whether you’re in the USA, Australia, New Zealand…anywhere.

So what is it, what’s the problem?

The problem is quality.

The person who is supplying your wire can not guarantee you quality. But you think to yourself, it can’t be the wire, no way. I’ve been using this (xxxx) brand wire for ages. They are a huge massive company, they sell MIG’s, TIG’s all sorts of welding gear no way can it be the wire that’s giving me problems….can it?

The trouble is that unless you are guaranteed the quality of you welding wire your “up a creek without a paddle”, so to speak.

With so many people selling welding wire these days it is extremely hard to come by a quality wire. The majority of goods made in the world today come from China or India. With huge populations and low wages, they are the cheapest places to buy things from.

There are over three hundred manufacturers of welding wire in China alone. What does this mean to the quality of your MIG wire?

This means that if the brand of wire on the box is (xxxx) they are not the manufacture of it. You need to ask the sales person….ARE YOU THE MANUFACTURER OF THIS WIRE?

Because what happens behind the scenes is the company you bought the wire from has a big argument with their supplier in China or where ever. And they say stuff ya….well go next door and buy from them. Hey with over 300 manufacturers in China alone they can pick and choose who they like.

So they change their manufacturing supplier, and this happens all the time. But when they change manufacturer the quality also changes. That’s why your wire has gone bad. And that’s why they can’t guarantee you the quality.

Simple as that.

Each time they change their manufacturing supplier the quality changes as well. There is a huge difference in quality of wires.

Okay so what do I do now, which wire do I buy?

The secret is to buy a wire that is supported by the manufacturer. You need a manufacturer that has been producing quality welding wires for years and years so that they have the art perfected.

Did you know that there are general “quality” mig weldng wires and precision MIG wires? Which type of wire do you think that the big boys use? When I say that I mean vehicle manufacturers, earth moving manufacturers and so on, companies that use it by the tonne. What do you think they are after in a welding wire?

They are after:

o Precision o Reliability o Repeatability o Consistency o Quality o Accuracy

How much money would Toyota or Mitsubishi or Caterpillar lose per minute if a welding machine was down? I sure bet it would be an awful, awful lot of money. These manufactures don’t want a single welding machine in an assembly line to break down. Cause if one thing stops, the whole show stops.

Welding is the method by which two metal pieces are connected firmly to make them compact and solid. Architectural and Industrial structures have a need of high-class and well-known welding services in order to carry out this kind of complicated job. High-quality welding necessitates toughness and potency and will never ever compromise on protection, security and cleanliness and safety. Structural welds have to be looked over, studied and inspected every now and then to make certain that there are no discontinuities which may effect to some harms and dangers or hazards in the future. Some zones of businesses and industries require the welding services and processes in some context. The following are some of the intricacies of the welding services that you should know in order to understand fully the matters concerning this line of work.

Commercial welding companies are stringent in providing work for only experienced and trained welders who are professionals in knowing the accurate heat to be directed while welding. Their overall work shouldn’t seem to be hulking or potholed which means the weld is not consistent and the holes and cracks might turn up henceforward.

Moreover, there are some food and hospitality industries that make use of several welded steel paraphernalia. Premium steel known as 304 is utilized here for the reason that it is not prone to corrosion, without doubt. The welding services in this industry should be completed with grand accuracy to put off bacteria and other dangerous and harmful effluents from polluting and contaminating the foodstuff, which is a risk if there are not smooth or fractured segments in the equipments. So, in order to make certain that you will not experience this, you have to get the welding services that can ensure maximum safety. Thus, TIG welding is suggested here.

The many welding services can be prepared in diverse ways specifically gas welding which makes use of the heat and the flame from burning gas. In addition, propane torches are also utilized to weld minor items which have need of only a smaller amount heat. On the other hand an Oxyacetylene torch is the most extensively employed welding contrivance. Nevertheless oxy-propane is a more cost-effective and easy on the pocket alternative to both the aforementioned types. MIG welders, TIG welders, AC and DC welders are utilized for superior projects and weighty equipments.

In a nutshell, all accredited welders and welding services providers are capable of giving you the welding services that you need for your home and personal business enterprise. But making sure that they have a certification program even qualifies them as accomplished workers. The excellent standards continue to live all over the country as well as in the neighborhood. Experienced welders, until the end of time, make certain that their welds are in good health ground, smooth and out of sight. Deformation is negligible in the work they do. Skilled welders are always and forever acquainted with the tricks for the different types of specialty welding and grinding, as well.

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Welder is constantly changing the way welding equipment and welding supplies with the advent of the internet to sell welding products for example welding rods and wire, welding machines, welding helmets safety products.

Welding supplies company requires connect the power of the internet to access more discriminating market. Earlier period, wholesalers can control welder manufacturers, distributors and other welder channels in the industrial sector. These obsolete ways of doing business are slowly disappearing due to the handiness of online shopping. Any welder can simply find welding supplies online; compare pricing to make an educated purchase in order to save money on welding equipment needed for the welding job to perform with skill.

All welding products searched on the internet because of readily accessible welding supply firms now online. Welding supplies for welding machine such as tig welding, mig welding, arc welding, plasma welding and gas welding can be found on the web to make shopping easier.

Welding manufacturers will be faced with the hard choice and old welding supply agreements with large welding equipment supply firms can compete toe-to-toe and offer enhanced service.

A vast way to grow with the welding industry is to identify the need to sell welding products in effective ways and meet the changing demands. Some welding supply firms have been around for many decades, the lure of selling their welding equipment online is too great to ignore. Welding equipment and welding supplies in any other fashion? Just by sheer convenience alone is enough incentive to convince any welder to consider buying from online welding supply company.

Is radiographic and / ultrasonic test required to be carried out at site for checking the quality of fillet weld in structural steel sections ? If yes, then how ?? If no, what other tests are required for checking the quality of fillet weld at site ?