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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.

It is an undeniable fact that welding aluminum items calls for some professional expertise and special skills. Even welding enthusiasts who have past experience in successfully welding steel will find aluminum welding challenging. The reason is simple – it is difficult to feed aluminum wire which is soft. Furthermore, wire diameters and machine settings generally used for steel may not be appropriate for aluminum.

The truth is with some practice, you will be able to tackle aluminum welding jobs such as grills, railings, backyard furniture, boat docks and even decorative elements – using a compact MIG welder. Depending upon your needs, you can buy the right type of MIG welder.

A 115 volt wire feeder welder can handle jobs that range from 22 to 12 gauge and with moderate pre-heating, you can probably weld even up to 1/8″ thickness. The only precaution is the preheating should not exceed 250 degrees F maximum. You can also opt for a 230 volt machine which can weld from 22 gauge up to 3/16″. If proper preheating is done you can go up to 1/4″. If your application is broader range of aluminum thicknesses, then it is worth investing in the 230v machine.

However, it needs to be stated that a compact MIG welder of 115 volt and 230 volt models are in order only for occasional aluminum jobs. As regards heavy duty aluminum, you must buy a welder that has greater than 200 amps output.

The next question you need to address when selecting a welder is whether you want a continuous or tapped voltage control model. Please understand that a continuous voltage control model lets you set an infinite range of voltage within the rating of the machine. This facilitates your adapting the voltage to your particular applications and skill level. If you want to spend less, opt for the tapped control unit. This machine has a rotary switch with four or five fixed voltage choices. This model will be adequate for most applications.

As already stated earlier, MIG welding aluminum is different from welding steel and this also applies to shielding gas requirements. For aluminum, 100 percent argon is the preferred choice, whereas steel welding calls for a mixed gas or 100 percent CO2 gas. Of course, for this reason no special equipment is needed – your existing regulators and gas hoses can be used for both pure blends and mixed gases.

The oxide layer needs to be removed from the aluminum immediately before welding. The edges of the aluminum should be cleaned with a file. It is best to use a new wire brush that hasn’t been used on steel, and to brush in a single direction so the oxide is not rubbed into the aluminum.

Please know that all MIG welding on aluminum materials requires electrode positive polarity. If you are switching your wire feed welder between processes, do not forget to switch your polarity. You will certainly not succeed in obtaining good results attempting to weld on aluminum with a steel wire electrode.

There is a trick to properly loading aluminum wire into a wire feed welder and this comes with regular practice. As you are welding aluminum, keep the gun cable as straight as possible to minimize feeding restrictions on the soft aluminum wire. Ensure that there are no bends in the gun cable that may make the wire kink and feed poorly.

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TIG welding is considered as the most  flexible process of welding as it can easily be merged with all the conventional metals such as Carbon and low alloy steels, stainless steel, nickel alloys, aluminum, magnesium, titanium, cobalt, and copper alloys. TIG welders also known as the Tungsten Inert Gas Welders makes use of an arc which is been created from the non-consumable tungsten. The heat is generated through electric current for the welding process.

Moreover, this kind of welding has several benefits like the high amperage in it allows the welding of metals with great thickness; also it include the concerns related to the purity of metal and its cleaning. In addition, welding is known as a skilled technique that requires lot of practice, patience and safety gear. TIG welder is one specific kind of welder. TIG welder is mainly used for complex and stylistic welding. Described below is certain tips that you need to consider while using TIG welders.

Instructions

1. Make sure to pick the better electrode in order to use for the project you are starting with; also you can make use of variety of alloys such as the 6061 Aluminum alloy electrode.
2. You need to grate the electrode to a certain point. Try to create a tip and sharpen it to make it more rounded as you weld.
3. Place the electrode into an electrode holder with the tip about 1/4-inch away from the case. You can choose the settings on your TIG welder. In fact, the three major ones are AC, DCEP and DCEN. You can choose AC for aluminum.
4. Remember to set the air on for five seconds with the max amps to 250. Also, turn on the gas. While using aluminum, you can use pure argon. For steel, an argon and carbon dioxide mix.
5. Scrub your welding table or the flat piece of sheet metal with a wire brush in order to make it clean and flat.
6. You can gear up the full welding safety gear including glasses, apron, helmets and gloves.
7. Always, hold the electrode in your dominant hand and you can start up your welding project.
8. You need to check your settings frequently to make sure they have not changed and you can adjust them as required.

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If you’re already looking at getting your Welder Associate’s degree in Florida or anywhere in the rest of the country, you have probably heard about how much demand there is for qualified welders in the industry.

There are lots of high paying, entry level welding jobs available to qualified welders who have passed their certification tests. Since welding regulation is so granular in the United States and the qualifications are so different based on where you got your welding associates degree or other welding training, it’s important to have good core education to back you up as you search for a fulfilling and lucrative welding career.

Many Welding Opportunities Available In a Variety of Locations

There are many different choices for someone who has attained a Welder Associate’s degree. Some pay much better than others.

• Entry-level “roustabout” welding job on an off shore oil rig can pay up to $60,000 a year, and workers typically get half the year off.

• Joining a local welding union will also help you get steady work with good pay. It’s common knowledge that union jobs pay better than non-union jobs. If you have a more artistic bent working in a custom design shop or machine shop could be a perfect application of your welding skills.

• Pipe welders often make more money than those who can’t weld pipes. Also, welders who can successfully weld different materials such as aluminum and stainless steel are also in high demand and can get paid a lot more.

• Different types of welding have different applications and different pay scales. MIG welding is common and is the easiest type to perform. TIG welding is harder and typically those who are successful TIG welders do well.

Getting an Associate’s Degree is a Great First Step for a Welding Career

The key to finding a welding job that can make your monetary dreams come true is to succeed in the field to begin with. Getting a welding associate’s degree from an accredited welding school is the most important step because that training will help you get a foot in the door so that you can continue your practical education on the job.

There are about 2000 eye injuries reported everyday in US workplace. Most injuries occur due to lapses in the usage of protection gears. Flying particles are the reason for 70% of injuries that are related to eye. These injuries can be avoided hands down by wearing the right kind of protective gear required for the job. Welding is in itself a hazardous job. Welders work in an environment that is subject to arc and heat rays, slag from chipping, flying metal and dirt from grinding. Therefore it is most important to choose the protective gear that suits the work type and to wear it consistently. Tips to injuries:

Inspect your welding equipment for any damage. Keep your equipments void of rust by maintaining it properly. Proper selection of protective gear according to the type of work and intensity is very vital. Protective gears should be at reachable distance. Always make it a point to use the safety gears while handling the welding equipments. Wear the eye protection gears under your safety helmet. If your welding helmet has the auto darkening option, you can work peacefully without having to adjust the shade manually. Wearing the right shade of filter in your eye gear is very important. Welding areas are harmful place of work. They should be secluded from rest of the place of work by a curtain that can absorb welding rays. Read manufacturer’s instruction manual thoroughly. And follow the instructions religiously. Keep your cables away from other tools so that they last longer. Avoid usage of cables that are undersized, damaged or spliced. Look for advice of the manufacturer for periodic maintenance activities to be performed on your welding equipment. Keep your helmet down to minimize your chances of injuring your eye from flying particles. Always choose an eyewear that has side shields or goggles and a correct filter shade to protect your eyes. Make sure your safety eye gear meets the heat, filtering and impact requirements. Timely replacement of faulty components will aid in longevity of the equipment. If your welding work is more frequent then it is wise to go in for a welding apron or a welding jacket. Vinyl screens or transparent welding curtains can be used to keep you protected from the harmful rays. Keep your arc welding equipments well insulated to avoid shocks. The workplace should be well ventilated. This will bring in fresh air and flush out the harmful fumes or gases that arise out of work. Laser welding are extremely dangerous to your eyes. Please follow the safety instructions pertaining to the equipment meticulously.

If you’re already looking at getting your Welder Associate’s degree in Florida or anywhere in the rest of the country, you have probably heard about how much demand there is for qualified welders in the industry.

There are lots of high paying, entry level welding jobs available to qualified welders who have passed their certification tests. Since welding regulation is so granular in the United States and the qualifications are so different based on where you got your welding associates degree or other welding training, it’s important to have good core education to back you up as you search for a fulfilling and lucrative welding career.

Many Welding Opportunities Available In a Variety of Locations

There are many different choices for someone who has attained a Welder Associate’s degree. Some pay much better than others.

• Entry-level “roustabout” welding job on an off shore oil rig can pay up to $60,000 a year, and workers typically get half the year off.

• Joining a local welding union will also help you get steady work with good pay. It’s common knowledge that union jobs pay better than non-union jobs. If you have a more artistic bent working in a custom design shop or machine shop could be a perfect application of your welding skills.

• Pipe welders often make more money than those who can’t weld pipes. Also, welders who can successfully weld different materials such as aluminum and stainless steel are also in high demand and can get paid a lot more.

• Different types of welding have different applications and different pay scales. MIG welding is common and is the easiest type to perform. TIG welding is harder and typically those who are successful TIG welders do well.

Getting an Associate’s Degree is a Great First Step for a Welding Career

The key to finding a welding job that can make your monetary dreams come true is to succeed in the field to begin with. Getting a welding associate’s degree from an accredited welding school is the most important step because that training will help you get a foot in the door so that you can continue your practical education on the job.