Spot welding, a form of resistance welding, is a process used to join two or more metal sheets together by applying pressure and heat to the weld area. It involves the use of electrodes, typically made of copper, to apply an electric current to the metal pieces. This current generates heat due to the resistance in the materials, causing the metals to fuse together at a specific point or “spot.” The process is highly efficient for welding thin sheets of metal and is widely used in various industries due to its speed, reliability, and cost-effectiveness.
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The evolution of spot welding machines has been marked by significant technological advancements. Early spot welders were large, stationary machines operated manually or by simple timers. As the demand for more precision and efficiency grew, technological improvements were made. The introduction of pneumatic and hydraulic systems allowed for better control over the welding pressure, enhancing the quality and consistency of the welds.
In the mid-20th century, the development of transistor technology and microprocessors brought about a new era in spot welding. Modern spot welders are equipped with sophisticated control systems that allow precise regulation of welding parameters such as current, force, and time. This has enabled the production of high-quality welds in a variety of metals and alloys, including those with high electrical conductivity or unique thermal properties.
Today, spot welding machines continue to evolve with the integration of advanced technologies such as robotics and computer numerical control (CNC), which offer greater automation, precision, and efficiency. These innovations have expanded the applications of spot welding in various industries, including aerospace, electronics, and construction, making it an indispensable tool in modern manufacturing processes.
This guide aims to serve as a comprehensive resource for understanding and navigating the complexities of spot welding machines. Our goal is to provide you with the essential knowledge and insights needed to make an informed decision when selecting a spot welding machine. We will navigate through the technical aspects, practical applications, and key considerations, ensuring that you are well-equipped with the information necessary to choose a machine that best suits your specific needs and applications. Whether you are a seasoned professional or new to the world of spot welding, this guide is your comprehensive companion, designed to demystify complexities and guide you towards a confident and informed choice in your spot welding endeavors.
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Shop Spot WeldersSpot welding machines come in various designs and configurations, each suited to different applications and work environments. Understanding the types of spot welders available is crucial in selecting the right equipment for your specific needs. Here, we explore four primary types of spot welding machines: Portable, Bench, Pedestal, and Robotic Spot Welders.
Each type of spot welding machine offers unique benefits and is suited to specific applications. Understanding these differences is key to selecting the right spot welder for your specific requirements, ensuring optimal performance and efficiency in your welding projects.
Spot welding machines consist of several critical components that work together to ensure efficient and effective welding. Understanding these components is essential for anyone looking to use or purchase a spot welding machine. This section covers the key components: Electrodes, Transformer, Controller, and Cooling System.
Each of these components plays a vital role in the operation of a spot welding machine. Understanding their functions and maintenance requirements is key to ensuring the longevity and efficiency of the equipment, as well as achieving high-quality welds in your projects.
Selecting the right spot welder requires careful consideration of various factors to ensure that the equipment meets your specific needs. Here are key factors to consider:
The thickness and type of material are among the most critical factors in selecting a spot welder. This is because different materials and their thicknesses have unique electrical and thermal properties, which significantly influence the welding process. The effectiveness of a spot weld, in terms of strength and quality, is highly dependent on the welder’s ability to provide the appropriate amount of heat and pressure. Materials with high thermal conductivity require more energy to reach the necessary welding temperature, while those with high electrical resistance generate more heat at the weld point.
Considerations:
By giving careful consideration to the material thickness and type, you can select a spot welder that not only meets your current needs but also offers the versatility to handle a variety of welding tasks, ensuring a valuable and long-term addition to your welding equipment.
The power requirements of spot welders are a critical aspect to consider, as they directly impact the machine’s performance and suitability for specific tasks. Spot welders are rated based on the electrical current they draw, typically measured in amperes (amps). This rating is not just a measure of the power consumption but also an indicator of the welder’s capability to generate the necessary heat for welding.
Electrical Infrastructure:
The existing electrical infrastructure of your workspace can greatly influence the type of spot welder you can effectively use. Not all electrical setups are created equal, and some welders may have specific requirements that need to be met.
By thoroughly understanding and evaluating the power supply requirements and the electrical infrastructure of your workspace, you can ensure that the spot welder you choose not only fits within your current setup but also operates efficiently and effectively, providing the desired welding outcomes.
The duty cycle is a critical specification in spot welding machines, indicating the duration a welder can operate at a specific output without the risk of overheating and needing a cool-down period. It is expressed as a percentage and is typically based on a 10-minute cycle. For example, a duty cycle of 60% means the welder can run continuously for 6 minutes at the specified output and then must cool down for the remaining 4 minutes.
Understanding Duty Cycle in Practical Terms:
Selection Criteria:
Additional Considerations:
By understanding and considering the duty cycle in the context of your specific welding needs, you can select a spot welder that not only fits your operational requirements but also ensures longevity and reliability of the equipment under the conditions in which it will be used.
The control system of a spot welder is a key factor that determines the precision, ease of use, and versatility of the machine. Control systems in spot welders range from simple to highly sophisticated, catering to different levels of welding requirements and expertise.
Automation Needs:
Considering the control systems and automation needs is crucial in selecting a spot welder that not only meets your current requirements but also aligns with future growth and technological advancements in your welding processes.
The physical size of the spot welder is an important consideration, especially in environments where space is at a premium. The dimensions of the welder should be compatible with the available workspace, not only for operational efficiency but also for safety and ease of use.
Portability: Portability is a key factor if the welder needs to be moved regularly, either within a single facility or to different locations. Portable welders offer flexibility but may have trade-offs in terms of power and capacity.
Balancing Size and Functionality:
By carefully considering the size and portability of a spot welder in relation to your workspace constraints and mobility needs, you can select a machine that not only fits physically in your environment but also aligns with your operational workflow and flexibility requirements.
These common features across various spot welders highlight the focus on precision, efficiency, safety, and user-friendliness in their design, catering to a wide range of applications from automotive bodywork to industrial fabrication.
Safety is paramount in any welding operation. Spot welders, with their high electrical currents and heat generation, come with inherent risks. Therefore, it’s crucial to consider the safety features of a spot welder to protect both the operator and the equipment. Here’s an expanded look at essential safety features and compliance standards:
Essential Features:
Compliance:
By prioritizing safety features and compliance with safety standards, you not only protect the operators and other personnel but also ensure the longevity and reliability of the spot welding equipment. This proactive approach to safety can also help in avoiding costly accidents and potential legal issues.
A tool balancer is a device used to suspend and balance heavy tools, like spot welders, in a position that makes them easier and safer to manipulate. It is particularly useful in reducing operator fatigue, improving precision, and enhancing safety in repetitive welding tasks.
Benefits of Using a Tool Balancer with a Spot Welder:
Choosing the Right Tool Balancer:
Installation and Usage Tips:
Safety Considerations:
Incorporating a tool balancer with a spot welder can significantly improve the ergonomics and efficiency of welding operations. By carefully selecting, installing, and maintaining the tool balancer, you can enhance the overall safety and productivity of your welding tasks.
By carefully evaluating these factors, you can choose a spot welder that not only meets your current requirements but also offers flexibility for future projects. This approach ensures a wise investment in equipment that will serve your welding needs effectively and safely over time.
Routine Maintenance Tips:
Safety Precautions and Best Practices:
Troubleshooting Common Issues:
Regular maintenance and adherence to safety practices are crucial for the efficient and safe operation of a spot welder. By proactively addressing maintenance needs and following best safety practices, you can ensure the longevity of the equipment and the safety of its operators.
Advances in welding technology continue to create efficiencies for the businesses who adopt them. Applying best practices help ensure weld quality and efficiency.
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Welding can range anywhere from simple joins and primary connections to fantastically elaborate art, but it all boils down to a small handful of techniques leveraged with mastery. Even master welders needed to start somewhere, and that somewhere is learning the different kinds of joints. Of the five types of joints, the Tee Joint is among the easiest to understand.
Welding can range anywhere from simple joins and primary connections to fantastically elaborate art, but it all boils down to a small handful of techniques leveraged with mastery. Even master welders needed to start somewhere, and that somewhere is learning the different kinds of joints. Of the five types of joints, the Tee Joint is among the easiest to understand.
Different welding joints refer to various positions and angles of the two pieces of material being welded together. Tee joints are one of several kinds of joints, including butt joints, lap joints, and others.
Tee joints, also known as T joints, refer to the shape of the materials making a perpendicular connection, like a T. It doesn’t have to be precisely 90 degrees, but a right-angle connection is by far the most common. Though deceptively simple in shape, you can make tee joints with various weld types.
Tee joints are most often used when the requirements are simple: two materials need to be connected perpendicularly and aren’t shaped oddly. They are also common in machine applications and structural welding. Think table legs attaching to a table or pipes to a cross-member for a railing.
A tee joint may be welded on one side of the material, or it can be welded on both sides. For example, when joining two flat pieces of metal, both sides of the vertical member are easily accessible and can be welded. When joining a pipe to a flat surface, the outer side is accessible, but the inner is not. Additionally, for added penetration and strength, the weld may use plugs from the back side of the cross-piece.
In welding, it’s important to distinguish between a weld and a joint. Both are essential to any connection, and knowing which to use in which situation is part of learning and mastering welding.
A weld is a method in which two materials are joined, and any grinding or drilling is necessary to prepare the materials. Different kinds of welds lend different types of strength to the resulting joint. The most superficial tee joints are welded using a primary fillet weld; the materials are placed against each other, and the weld adheres them together. More complex versions involve beveled welds, J-welds, plug welds, slot welds, or melt-through welds.
So: a joint is the position of the materials, and a weld is how they are connected.
The needs of the finished product largely determine the choice of the weld. For example, a simple fillet weld is usually satisfactory if the joint is mainly cosmetic and does not need a high degree of strength. Conversely, if the joint is expected to bear significant loads or withstand lamellar tearing, more thorough preparations will be necessary.
Tee joints are simple joints with many avenues to make them more complex and robust.
Typically, a tee joint is simple and relatively easy/fast to produce. When done correctly, tee joints can be pretty strong. However, they must be done correctly; if the materials are thick, you must prepare the edges, and additional support may be necessary.
The most significant risk is lamellar tearing, where the base material cracks due to inclusions and imperfections in the metal, and the contraction is caused by the welding heat. Lamellar tearing occurs because of tensile stress, which can limit the utility of the tee joint.
Tee joints can also be deceptive. With basic fillet welding, a joint can look and feel solid while only being adhered to on a surface level, meaning the joint will be prone to failure. With thicker materials or materials that will need to bear the stress, you must ensure that proper penetration into the metal fully adheres to the pieces.
How to Weld a Tee Joint
Welding a tee joint is simple, and it’s often a great introduction to welding. Here’s how to do it. For this article, we assume that you’re using an appropriate kind of welding (between stick, TIG, and MIG) and that you have the necessary equipment. If you’re still learning, your mentor should be able to provide you with what you need.
As a quick primer:
Picking the right kind of welding is essential. However, as a beginner, you will likely be starting with either stick or MIG welding and learning the ins and outs of the process before digging deeper into the most appropriate kind of welding for each job.
Welding, when done correctly, is a safe process for both hobbyists and career practitioners. However, it has many different ways to go wrong, so safety is paramount.
Make sure you have an appropriate safety checklist before starting any weld.
Welding safety is critical, so take this step, no matter how deep into welding you delve.
Impurities are the enemy of solid welds. Before welding metal, you must prepare that metal. There are two kinds of preparation; you must do the first for every joint, and the second depends on the type of weld.
To prepare your materials, you’ll need an angle grinder to remove surface materials, mill scale, dirt, paint, and any other impurities that can get between the two pieces of metal and your filler material. Remember lamellar tearing? Lamellar tearing can be minimized or avoided in various ways, including cleaning. Welding two pieces without adequately cleaning them will result in those impurities baked into the weld, weakening it for inevitable failure.
It’s also a good idea to clean a spot for your ground clamp to ensure a solid connection and reduce the risk of stray shocks.
At this point, you would typically be thinking of what kind of joint to use, but as we’re discussing tee joints, that choice is made for us. So, now you must consider what type of weld to use.
Note that the choice between a J or a V bevel primarily comes down to the tools you have on hand. A J is usually better if you have a tool to produce the bevel. J welds are slightly more robust and easier to do but are harder to bevel by hand uniformly.
Basic fillet welding is fine for practice welds or simple bevels to practice something more complex.
High-quality welding requires even, thorough, steady handling of your welding gun. To facilitate this, you want yourself and your materials to be positioned such that you need to move as little as possible to perform the weld. Practice moving the gun across the weld, maintaining a steady hand. Reposition if you encounter something in your way or would otherwise need to reposition mid-weld.
Next, you’ll want to secure the two pieces using a tack weld. Tack welding is performed by making small dots of weld to hold the materials in place for the final weld. This step is also your last opportunity to verify accurate positioning, angles, and squaring of the materials. No one wants to weld a T only to find it looks more like a 7!
After you have tacked the vertical member in place, you are ready to begin the final weld.
You move your welding gun over a joint and deposit filler material when welding a joint. The pattern in which you do this is called a bead. The simplest bead is a stringer, a single straight bead across the joint being welded.
Different kinds of beads allow you to create more comprehensive welds and better control the heat in your weld. For example, this image shows multiple motions, such as waves, triangles, and ladders:
Other types of beads include weaving actions of various sorts. You can learn more about these kinds of beads here.
A simple stringer bead is all you need for a practice weld and a beginner welder. Later, you can practice other kinds of beads, different positions for welding, and different circumstances in which welding can go wrong. After all, it’s just as important to know how things fail as it is to understand how they go right, so you can recognize it and learn to adjust.
If your materials are particularly thick, you may need to lay more than one bead. You may also need to return to step 2 to re-clean the weld for a second pass to prevent slag from contaminating and weakening the joint.
Once your weld is complete, it’s time to finish it.
If your weld is not going to be visible, or if the overall look of the weld doesn’t matter, then you’re done. Unfinished welds can look beautiful in the hands of a professional, but they may also be susceptible to rust when exposed to the elements. Welds are often the first area in construction to rust.
So, you may need to finish the weld. Completing a weld can involve:
If you are planning to grind your joint, you should exercise caution. It’s effortless to over-grind and to weaken (or even remove) your weld entirely, separating your pieces and leaving you back at square one. While that can give you a good source of another round of practicing, it’s not a habit you want to get into.
Welding is an essential skill for any tradesperson, and at the same time, it is one of the most satisfying. There are many different types of welds, but the tee joint is one of the most common, so if you’ve been looking for a good beginner’s guide, this should help.
We recommend reading these two articles for more information on the basics: welding safety and welding equipment.
If there’s anything in particular that you’re wondering about, then please don’t hesitate to contact us!
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Steel and aluminum (and its alloys) are among the most widely used structural materials in the world. Steel has been used by human beings for several millennia in construction, transportation, warfare and many other industries. Aluminum doesn’t have nearly the same tenure being only discovered by Hans Christian Ørsted in 1825 and the ore refining process being more complex than iron ore.
Ever since its discovery aluminum has gained extensive use due to its low weight compared to most metals. Due to the desire for more lightweight designs, aluminum is becoming increasingly employed. However, steel and other alloys have significantly higher strength and higher operating temperature than aluminum. The requirements for high strength from steel and lower weight in aluminum generate the need for steel-aluminum dissimilar joining.
Steel and aluminum are rarely, if ever, directly welded together via fusion welding like TIG and MIG welding due to the brittle intermetallic compounds that form in the fusion zone. The brittle intermetallic compounds may affect the ductility of the weld and high temperature properties of both metals. The specific intermetallic compounds formed largely depends on the specific steel and aluminum alloy being formed. Additionally, steel and aluminum have different coefficients of thermal expansion, so in elevated or cryogenic temperatures, the steel and aluminum will be subject to thermally-induced stresses since the metals will not expand at the same rate.
There are a few solutions if you find yourself in need of steel-aluminum welding. Starting with the simplest option, bolting and fastening is one way to join steel to aluminum while avoiding several of the drawbacks. As long as the steel-aluminum joint is primarily structural, bolting is one of the more cost-effective ways of joining. Bolting and fastening, however, is not recommended to for joints that must be seamless such as for a pipe joint because the joint is not airtight or watertight. Furthermore, bolting aluminum to steel requires electrical insulation in the presence of salt water or other conductors. A plastic washer will accomplish the electrical insulation goal. Keep in mind that using a plastic washer may limit your operating temperature.
Another well-known option is inserting an interlayer prior to welding. The purpose of the interlayer is to provide a “barrier” to direct interaction between steel and aluminum, preventing the formation of the intermetallic compounds. Additionally, an interlayer can help ease the thermal stresses induced by the difference in coefficient of thermal expansion (CTE) Thus, the interlayer must be thick enough to prevent interaction between iron and aluminum and, in the case of thermal and cryogenic, have a CTE between steel and aluminum.
Most interlayers for steel-aluminum joining are bimetallic transition inserts that can be purchased from many companies. Bimetallic inserts for steel-aluminum welding are typically aluminum in one section and steel in the other. When welding with bimetallic inserts, always consult the manufacturer documentation for proper utilization and details about the metallic insert composition, but most are compatible with MIG, TIG, and GMA welding.
Not that not all aluminum alloys and steels are the same or have the same weldability. For instance, some 7000 series of aluminum tend to be difficult to weld. Be mindful that commercially-provided bimetallic inserts are meant to fit specific structures and not necessarily suitable for more customized or irregular structures. Therefore, do proper research before purchasing a bimetallic insert.
Some academic articles report using a copper interlayer for joining steel to aluminum. Keep in mind that copper can form intermetallic phases with aluminum, some of which are beneficial to aluminum, and does not tend to do so with steel. Another interesting development was using a Al0.5FeCoCrNi interlayer to weld 6061-T6 aluminum to St-12 low carbon steel in an academic article published in the Intermetallics journal in 2020. Using a material other than marketed bimetallic inserts may have more flexibility in terms of accommodating customized or irregular structure and may come as a foil, welding wire, or powder.
The last common steel-aluminum joining remedy is to coat one or both sides of the joint with a different metal prior to welding. The most common one for steel-aluminum welding is hot dip aluminizing which coats the steel side of the joint with aluminum. When using this technique, only melt the aluminum and be sure that the arc does not touch the steel! Touching the steel with the arc will cause the aluminum coating and the steel to melt and react to form intermetallic phases. While the aluminum coating does adhere to the steel, it is not actually bonded and the strength of the joint is not as strong as steel-steel or aluminum-aluminum joints.
Other coatings can be used such as copper when welding aluminum to steel. For hot dip coating, it is generally a safer bet to coat the steel since aluminum would also melt in a pool of liquid copper. In general, dip coating is more flexible than using bimetallic inserts since dip coating can conform to most geometries.
Electroplating is a “cold” coating option that does not involve any molten metal and is not used as frequently for welding compared to the above options. Electroplating uses controlled electrolysis to transfer the desired metal coating from the anode (made of the same metal as the desired coating) to the cathode (the part being plated). Aluminum can be electroplated with copper, but steel cannot. If you choose aluminum as the piece to be electroplated, your joining options are typically limited to spot welding, high-precision laser welding, brazing, and emerging solid state welding processes.
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Keep in mind that electroplating can be a rather slow process that can take several minutes and the surface area of the workpiece that can be plated depends on the size of the container holding the plating solution and the amount of current you can generate. When electroplating, having a current or voltage that is too high will cause the plating process to proceed out of control as seen by dendrites growing on the workpiece surface.
If the cathode and anode are not parallel to each other, then the electric field that governs the electroplating process will be uneven and so will the coating thickness. The plating may have poor adhesion of the process is not well controlled or the surface is not well cleaned. If the current or voltage is too low then the electroplating will either be slowed or not work at all. As such, electroplating is recommended only for relatively small, flat work pieces and not large structural pieces.
One other consideration to note is the geometric requirements of your welding operation. If welding something with a very specific geometry like a hollow part made by additive manufacturing, you may consider using a brazing over welding to avoid damaging the structure via torch brazing or induction heating. Keep in mind this may require a filler metal that is guaranteed to melt before the geometry-sensitive part will melt and is compatible with both materials.
When considering your steel-aluminum welding needs ask the following questions:
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Whether you are a professional or amateur gearhead, the automotive shop you work in requires a lot of tools, technology, and know-how to bring a project from start to finish. In that process, welding is one of many critical skills in the world of automotive fabrication and repair. Like all skills, staying sharp on the tools and techniques used in automotive welding can certainly pay dividends by making your work higher quality, faster, and easier.
Welding Processes for Intake and Exhaust Fabrication & Repair
Intake and exhaust components often utilize either Gas Metal Arc Welding (aka MIG) or Gas Tungsten Arc Welding (aka TIG). When comparing the two processes, TIG offers a much greater degree of control at the expense of speed and ease of use while MIG offers improved speed and ease of use at the expense of precision. It is possible to fabricate complete systems using either process, but muffler repair shops working on consumer-grade and OEM components typically employ MIG, while custom fabrication typically employs TIG.
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If you’re searching for a welding machine, you may stumble across descriptions such as “transformer” or “inverter.” If you are unsure which is best for your application, at least know this: transformer and inverter welders are perfectly capable of producing high-quality welds. However, keep in mind that most new models produced by industry-leading manufacturers are inverter-based.
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Tungsten Inert Gas (TIG) welding—more formally known as Gas Tungsten Arc Welding (GTAW)—is well-suited for welding aluminum. Although the process is significantly slower than GMAW (MIG), TIG welding offers unmatched control of weld penetration and profile. This level of control is enhanced by the features available on modern TIG welders.
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When it is tough to bring the workpiece to a source of power, it is often necessary to bring the power source to the workpiece. By combining the capability of a welding power source with the functionality of a portable generator, the engine-driven welder generator often becomes one of the most versatile pieces of equipment on the jobsite.
Engine-driven welder generator rentals power all sorts of job sites. The “mobile welding rig”—a work truck outfitted with an “engine driven” welder— is a common sight alongside the spans of onshore pipelines, heavy equipment in need of repair, or structural and bridge construction sites. Of course, equipment trailers are a popular accessory for those who need to free up bed space.
A vast array of equipment power plants and feature sets ensure that both the home hobbyist and professional welding outfit can access the power and processes they need in the field. A home hobbyist unit may start out having a gasoline engine providing a 4.5 kW single-phase maximum output while some of the largest dual-operator units are diesel-powered and offer maximum three-phase outputs of approximately 25 kW.
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How did the Dual Maverick 200/200X get its name? When you glance at the front panel of this diesel engine-driven welder, you might start seeing double: two front panels and two sets of output lugs. As the name implies, the Dual Maverick 200/200X is a dual-operator welding power source. The 24.8 horsepower water-cooled Kubota diesel engine in the Dual Maverick has the capacity to allow two welding operators to weld independently of one another.
The alternative is to supply each welding operator with their own engine-driven welding machine, but this approach has drawbacks. Placing this extra equipment on the jobsite creates additional clutter and requires additional maintenance. Likewise, the one welder/one welding machine approach is less fuel-efficient. Lincoln Electric claims that a multi-user welding machine like the Maverick Dual 200/200X can reduce fuel and maintenance expenses by up to 33% per 1000 hours, which equates to approximately one year of “typical” use.
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Aluminum alloys continue to gain popularity in metal fabrication worldwide due in part to the ease with which these alloys can be fabricated—bent, welded, and most importantly, cut. The ease at which aluminum can be cut to shape and size can have a big influence on the cost and quality of subsequent operations and the final component itself. As with steel, the use of plasma arc cutting (PAC) on aluminum alloys is a popular choice for quickly producing high-quality cuts.
Speed is one of the greatest justifications for plasma arc cutting aluminum over mechanical cutting methods. Laser cutting can certainly exceed the speed of plasma but is not without its own process disadvantages. Waterjet cutting certainly has advantages over plasma from a metallurgical and edge quality perspective. Instead, cutting aluminum with plasma provides an excellent balance of speed, quality, and cost. Compared to these other processes, it has a notably lower capital investment and is also simpler to implement as a handheld process for in-service repairs in both the field and shop.
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Like shielded metal arc welding (SMAW, stick), Flux Core Welding (FCAW) is a popular welding process that uses the assistance of flux within a tubular wire to help produce high-quality welds. Unlike shielded metal arc welding, flux cored welding can be divided into two distinct processes: self-shielded flux-cored arc welding (FCAW-S) and gas-shielded flux-cored arc welding (FCAW-G).
Both the home hobbyist and professional welder will encounter situations where one process is advisable over the other. FCAW-G is most often used indoors, while FCAW-S is typically used outdoors. To maximize productivity and quality, welders should become familiar with the welding tools and equipment of both processes so that they can quickly setup and operate whichever process is best for their application and welding environment.
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Aluminum welding is one of the most critical processes in manufacturing. By understanding the challenges of aluminum welding, manufacturers can produce stronger and more reliable products. Aluminum is a unique material that requires special techniques to weld properly. It is valued for it’s lightness and is often used in aircraft construction. This guide will discuss the different steps involved in the aluminum welding process and why you must follow a specific protocol when welding with this material.
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With welding, as in many things, having the right tools is crucial. As a beginning welder, the appropriate equipment varies depending on the type of welding work you plan to accomplish. There isn’t a one-size-fits-all option; the proper welder for working in a steel mill or auto shop is often out of place on a construction site or in your personal workshop at home. A welder rental provides the opportunity to find the best fit for your needs.
To put your best foot forward, take the time to learn about the different types of welding and the equipment involved. As a newcomer to the field, you can discover the important facts in the following welder rental FAQ resource.
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When thinking about renting welding equipment, many contractors imagine visiting a local hardware shop with a small selection of soil compactors and other basic items. In reality, today’s rental solutions are nothing like that. You can find high-quality precision machinery maintained in optimal condition, from plasma cutters to TIG rentals
With professional welder rental, companies in countless industries are able to reach their goals on time and within budget:
Construction
Manufacturing
Aviation
Oil drilling
Industrial pipe welding
Transportation
Automotive assembly and repair
Specialty production and prototyping
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Many businesses perform welding tasks every day, including parts manufacturers, vehicle makers, construction businesses and repair shops. People who enjoy do-it-yourself projects can handle automotive tasks or home repairs with a good arc welder. Thanks to welder rental options, you don’t even need to purchase welding equipment to get the job done.
Two popular types of arc welding equipment are metal inert gas (MIG) welding and tungsten inert gas (TIG) welding. What are the differences? How can you decide whether MIG or TIG welding is the right method for your application.
MIG welding utilizes a welding gun with a machine-fed consumable wire. This metal wire serves as the electrode and provides the filler material for the weld at the same time.
While you work, the MIG welder delivers inert gas (usually argon) to shield the weld pool and protect the metal from contamination. The MIG welding gun automatically feeds more wire into the molten pool as you advance, so this option provides “what-you-see-is-what-you-get” welds that are easy to start, direct and control.
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In addition to portable stick, MIG, flux-cored and spool gun welding, the GX300XL also allows you to perform in-field Touch Start TIG welding with Pulse capability.
DC TIG Welding with Optional High-Frequency
For DC TIG welding without high frequency, the GX330XL is available with an air-cooled TIG torch, gas regulator, and a K780 Foot Pedal, and a K930-2 TIG Module can be included which enables high-frequency arc starting.
For AC TIG Welding, add a Square Wave TIG 200
For AC TIG welding with high frequency, you can power a Lincoln K5126-1 Square Wave TIG 200 (which includes a PTA-17 TIG torch and a K5126-1 Foot Pedal) from the 120/240 VAC dual voltage, full-power receptacle on the front control panel of the GX330XL.
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There are no shortage of reasons for current supply chain issues and correspondent price increases, but it would be safe to say that we’ve never experienced anything like this in recent history.
For contractors, fabricators and other industry segments that require welding services, it’s more viable than ever to consider equipment outsourcing as a means of fulfilling existing orders and contracts, not to mention the ability to quote on new business opportunities without having to worry about having access to the most suitable equipment in sufficient quantities.
The basic tenet of rental versus ownership, is the idea of paying for equipment use, without the complexities and inconveniences of the cost of equipment ownership. These costs are often referred to as “hidden costs” as they are frequently overlooked when determining the total cost-of-ownership. To cite just a few examples, fleet owners not only have to arrange for back and forth transportation of equipment to their job sites, they also have to arrange and pay for storage and servicing of the equipment when not in use. If the equipment becomes out of date due as a result of being superseded by a new product, or if a new welding process is required, they can be stuck with obsolete or non-suitable equipment that has to be disposed of, or at the very least, loses some of its utilization potential. For servicing, maintenance and troubleshooting challenges, paid in-house personnel or outside service shops need to be retained and relied on to keep the equipment up and running, as well as certified or calibrated to meet published operational standards.
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Aircraft repair is a huge business! In 2018, the worldwide economic impact for global aircraft maintenance, repair, and overhaul (MRO) was over $75 billion (USD), with an estimated compounded annual growth rate of 4.7% through 2025. The commercial air travel industry’s near-term growth outlook is 6.5%, with 20-year traffic growth projected at 4.0%. Welding is a standard maintenance practice in aircraft repair as described in the FAA Advisory Circular 43.13-1B. As welding processes and procedures have improved over the years, some parts that were once non-repairable can now be repaired by welding.
Welding is the most prominent form of joining metals in aircraft without the use of fasteners. The five types of metals welded in aircraft are 4130 steel, stainless steel, aluminum, magnesium, and titanium, each used in different areas of the aircraft. For example, 4130 was a prevalent building material in tube-and-fabric construction but is now limited to mainly aircraft used in agricultural applications.
TIG Welding is revolutionizing aircraft maintenance for repairs that fall outside of the original equipment manufacturer’s scope. Magnesium alloy is common in constructing transmission cases in helicopters because it is very strong and light; weight is everything in aircraft (particularly helicopters). Yet transmission cases were never made to be a repairable item. The original intention was to simply scrap damaged cases and replace them. However, a new transmission case can easily cost more than $50,000. Companies specializing in aero repairs have pioneered proprietary repairs on transmission cases and gearboxes that pass the FAA’s rigorous muster. These repairs can save upward of 90% off the bill of a new case or gearbox.
The approved method for magnesium cases is predominantly tungsten inert welding (TIG) for the extreme heat necessary to join the metal. Oxyacetylene can be used for this method of joining metals but it is not the best method due to base metal oxidation, distortion, and the loss of elasticity.
Tungsten inert welding (TIG, also known as Gas Tungsten Arc Welding) is an incredibly versatile welding method and can meet most of the demands of aircraft maintenance. Because of its relative simplicity and accessibility, oxyacetylene welding was the standard process for many, many years. Still, TIG welding has dethroned it as the go-to method in recent years, particularly as TIG equipment has become commonplace and come down in price.
In the early years of TIG welding, the inert gas most commonly used was helium, which gave rise to the early trade names of Heliarc and Heliweld. In time, carbon electrodes made way for the modern tungsten rod. We now find a highly versatile technique that is further enhanced by the ability to run either alternating current or direct current.
A TIG welder set for DC current, straight polarity, is suitable for all mild steels, stainless steel, and titanium typically welded during aircraft maintenance. 4130 is a low-carbon, chromium-molybdenum alloy and is very common in the composition of aircraft structures. The signature standard alloy is used in a tubular form for aircraft fuselages that employ a truss-type of construction. In commercial aviation, agricultural application aircraft (“crop dusters”) use this construction method exclusively because it provides a strong, rigid airframe.
Low-carbon steel is also widely used in the industry in the production of engine mounts for piston engines. For these parts, welding is the only method of repair available to help operators avoid purchasing new replacement parts. Considering a used engine mount from an aircraft salvage yard runs in the ballpark of $1,000 for a simple Cessna 172, fixing a cracked weld whenever practical is a much more cost-efficient solution.
Historically, aviation has been a hobby for the wealthy, and this is not just talk. If you have ever wondered why airplane owners speak openly about rebuilding their engines rather than replacing them with new engines, the figures will make it clear. Consider that a brand-new four-cylinder piston engine easily runs in the $40,000–$50,000 range. That’s not a misprint. A rebuilt zero-time engine for a Cessna 172 is still more than $20,000, and these are engines without turbochargers or superchargers.
Engine cases on aircraft piston engines are also often made out of magnesium alloys, for the same reason that gearboxes and transmission cases are: excellent strength-to-weight ratio. Unlike an automobile engine, which routinely only runs around 10%–15% of maximum output, aircraft engines operate at about 75% output during the cruise. Accordingly, their crankcases are subject to high stress and are prone to cracking. Also, since the engines are often repeatedly overhauled, the cases may have several thousand hours of use as opposed to the pistons and cylinder jugs, which are replaced at overhaul intervals. A new engine crankcase is predictably quite expensive, so the option to repair a crack by welding is far less costly.
The more complex the aircraft, the higher the cost of replacement parts. Turboprop turbine engine rebuilds (Pratt & Whitney PT-6A, Honeywell TPE331, etc.) often exceed hundreds of thousands of dollars. Fixing cracks and building up casting defects and damage is a cornerstone of cost-effective repair strategies.
Aircraft are exciting machines. They are flown through turbulent air at hundreds of knots, blasted with rain and wind, only to just about drop out of the sky and slam onto a hard runway. They are strong, yet they have to be light. Corrosion is a silent killer, and weight is the constant nemesis. Stainless steel and titanium are used in aircraft construction in critical areas where low weight and temperature tolerance are paramount.
Titanium is widely used in turbine engine compressors and stator blades, subject to constant high vibration, extreme heat, and foreign object debris (FOD) that routinely includes pebbles and rocks, rivet stems, screws, loose hardware, ice, and birds. It is a harsh environment where titanium components are easily damaged. TIG welding these damaged components to fill in and blend the damaged areas saves thousands of dollars and considerable time in commission spent waiting on parts. Instead, repairs can be performed often on-site, and the engine reinstalled quickly.
Stainless steel is ubiquitous on aircraft, often used in ducting and baffling throughout the aircraft, exhaust ducts or pipes, and a slew of other areas. When, for example, an exhaust duct on a turboprop crack (not uncommon), it can easily be removed and repaired, again saving a lot of money and a whole lot of time.
Aviation is one of the most heavily regulated industries in the world. The threshold of entry to new designs is so burdensome that old technology prevails. Also, old aircraft are commonplace. Many airliners, particularly cargo aircraft, are 20 to 30 years old, which takes a toll on metals prone to fatigue. Rather than replacing parts, it is fiscally advantageous to repair whenever possible, and most repairs boil down to a weld to fix the metal. Welded repairs continue to keep operators in the black and safety compliant in a transportation market where controlling costs and maintaining safety standards are essential considerations.
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