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New MAXAL 4943 Aluminum Filler Alloy

Thursday, August 15th, 2013

Looking for more strength out of your aluminum welds? Check out the latest aluminum filler alloy – the 4943 filler from MAXAL.

The new 4943 filler has exceptional gains in strength over 4043 filler and can be used anywhere 4043 was used and more.  This includes the 1XXX series, 3XXX series, 6XXX series and 5XXX series with 2.5 percent Mg or less, like the popular 5052 alloy.

Features include up to 40 percent gains in fillet weld strength, the ability to be heat treated (where 4043 cannot), and is ideal for A356 castings.  In the racing world, we’ve used it on spoilers, brake ducting, intake manifolds and tubing, radiators, oil tanks and even aluminum heads.

Higher strength means you can use smaller weld beads and less filler.  The Dynasty® series of welders can maximize applications using 4943.  The adjustable wave shape can give you the narrow arc focus and increase in total penetration, and the 4943 filler will add to the joint strength.

The savings in weld time and material deposition easily make up for the slightly higher cost of the 4943 over 4043, plus you gain strength and heat treat ability.

The only real limitation, which is no different than 4043, is that it does not color match well during anodizing.

Ask a dealer about trying the new MAXAL 4943 filler.

Andy Weyenberg
Motorsports Marketing Manager

Knowledge is Power: Weld Data Monitoring

Tuesday, July 24th, 2012

Nick Peterson, a welding engineer and curriculum developer with Miller, contributes a quarterly column to Fabricating and Metalworking magazine. In the most recent column, Nick discusses weld data monitoring and the benefits it provides manufacturing and fabrication applications, including improved quality, productivity, cost analysis, consumable savings and training.

Read the whole story by clicking here!

Weld data monitoring gives manufacturers and fabricators greater insights into the day-to-day activities in the weld cell.

Top Factors and Considerations for MIG Gun Selection

Tuesday, June 26th, 2012

Selecting a MIG gun (or torch) for your welding application should be done with just as much attention to detail as the welding power source itself. Think of it as the human body: an injured toe or finger inhibits our ability to perform basic functions such as walking or grasping. The gun — while an extension of the system — is just as critical to the quality of the weld itself and the productivity of your operators. There are also important considerations when selecting a MIG gun that may help you lower your operating costs. In this article, we’ll take a look at common types of MIG guns and considerations you should make when selecting the gun that’s right for you.

Read the whole story by clicking here!

K-zell Metals Drives Productivity with Pre-engineered Robotic Weld Cells

Thursday, March 29th, 2012

At a time when manufacturers are looking for new ways to diversify and compete against global competition, K-zell Metals, Inc. of Phoenix has been proactive in anticipating changes in the market through process improvement. Through the addition of two Miller PerformArc™ pre-engineered robotic weld cells, K-zell was able to substantially increase productivity (by more than 20 percent), reduce set-up time and find new efficiencies in its welding processes — even on relatively short production runs. A modular design allowed each system to be quickly dropped into the flow of the shop floor, and features such as offline programming have helped the company quickly take on new work with minimal start-up time.

You can read the whole story by clicking here!

Check out this series of videos from our time at K-zell, including an exclusive video not included in this case study on the benefits of the AlumaFeed™ Synergic Aluminum Welding System from Miller:

EXTRA: Aluminum Welding with the AlumaFeed System

About K-zell and Robotic Welding

The Case for Robotics

Offline Programming

Weld Fume Mitigation: Considerations for Source Capture and PPE

Friday, February 17th, 2012

What is a better solution for your welding application, a fume extraction device or a Powered Air Purifying Respirator (PAPR)? It comes down to the consideration of source capture versus PPE. In this article we take a look at considerations for choosing a system appropriate to your application. Bottom line: source capture is always preferred, but some applications require more personal protection.

Learn more and read the whole story here.

AGCO Relies on Weld Data Monitoring

Wednesday, February 15th, 2012

AGCO – one of the world’s leading manufacturers of farming equipment – continues to prove the strength of American manufacturing. The company has recently moved some manufacturing operations from France back to their plant in Jackson, Minnesota.

As the company continues to discover new ways to streamline its processes, weld data monitoring has become a huge part of their daily welding operations. The demands of more complicated designs, exotic steels and precise welding requirements called for more direct feedback to the operator at the point of the weld. The technology also helps management examine welding operations and data.

Learn more and read the whole story here.

Miller Welding Automation at FABTECH 2011

Thursday, November 17th, 2011

Miller Welding Automation is showcasing its industry leading automated welding solutions at FABTECH 2011 (booth 5954).

In these videos, Miller Welding Automation’s Brian Doyle discusses some of the highlights of the products displayed at the show. For more information on Miller Welding Automation, visit:

Adaptive Fill Welding Capabilities

Dual Robot Tandem Welding

Welcome to FABTECH 2011!

Monday, November 14th, 2011

The day we’ve all been waiting for is here – the start to another exciting FABTECH show. If you’re in Chicago, please make sure visit our three exciting booths in North Hall:

Miller: Booth 6154

Miller Welding Automation: Booth 5954

ITW Welding North America (Bernard, Hobart Brothers, Smith, Tregaskiss, Weldcraft): Booth 5950

We’ll be introducing new products and showcasing comprehensive welding systems and market-specific solutions. Key points of interest will be live welding demonstrations (including an aluminum-specific demo area), new advanced technologies such as the weld data monitoring capabilities of Miller’s Axcess E with Insight, and contests and giveaways from Miller’s Arc Armor brand of welding personal protection equipment.

As in previous years, you can follow along all the action on the Miller website by clicking here!

Here’s the first few videos straight from the show floor:

Welcome to FABTECH 2011!

Details on the Arc Armor Welder Protection Makeover

Miller’s Hero Photo Booth and Contest

We hope to see you in the booth! Have a great show!

Miller Seminars and Presentations at FABTECH 2011

Wednesday, September 28th, 2011

One of the best reasons for going to FABTECH 2011 is the extensive schedule of educational seminars and presentations designed to give you insight into industry trends and advancements. As always, Miller and its ITW partners are proud to take part in these seminars, and we’ve put together here a preliminary list of key Miller-related sessions you should keep an eye out for.

FABTECH 2011 is taking place November 14-17 in Chicago at McCormick Place.

Educational Annual Program: Monday, 11/14

Miller’s Bruce Albrecht will participate in an industry roundtable discussion of “Career Paths in Welding” from 11:30 am to noon and then again from 1:15 to 2:45 pm in room N131.

Educational Annual Program:  Tuesday, 11/15

Miller’s Rolando Sanchez and Paul Cleveland will give an educational reform presentation for welding educators from 1:00 to 3:00 pm in room N138.

8th Conference on Weld Cracking: Tuesday 11/15

Hobart Brothers’ Joseph C. Bundy will present “Understanding Weld Cracking in Steels” from 8:30 to 9:05 am in room N230B. Here’s a brief overview:

There is a great deal to be said about the consequences, the causes, and the remedies pertaining to weld cracking. In this presentation we will touch on all three and delve into the solidification and liquation cracking prevalent in hot cracking as well as the problems caused by diffusible hydrogen. The topics of pre- and postweld heat treat will also be examined.

Bruce Anderson from MAXAL will present “How to Prevent Cracking When Welding Aluminum Alloys” from 10:30 to 11:05 am in room N230B. Here’s a brief overview:

This presentation will examine the primary reasons for hot cracking to occur when welding the various aluminum alloys. It will evaluate the crack sensitivity associated with the various alloying elements that are added to aluminum and how we can use crack sensitivity curves to predict and thereby reduce the hot cracking potential of our welds. It will further discuss the importance of correct filler alloy selection and how the filler alloy/base alloy combination can be critical in the prevention of solidification cracking.

Tube and Pipe Joining & Inspection: Tuesday 11/15

Miller’s Jim Cuhel and Ron Halpenny of Graham Corporation will present “Regulated Metal Deposition (RMD™) Modified Short Circuit MIG and Pro-Pulse™ Pulsed MIG Welding Processes Advance Pipe Welding Performance and Productivity” from 10:30 am to 12:30 pm in room S503B. Here’s a brief overview:

Through a calm, stable arc and smooth metal transfer, Regulated Metal Deposition (RMD™) outperforms TIG and short circuit transfer MIG welding processes in pipe welding root pass applications by reducing rework and distortion, and providing process benefits such as faster travel speeds and the elimination of back purging on stainless steel. 

What’s New in Power Sources Program: Wednesday 11/16

Miller’s Todd McEllis will present “Modern Power Source Technology that Drives Process Improvement” from 8:30 to 9:05 am in room N231. Here’s a brief overview:

The goal of the welding industry is no different than that of other industries – improve productivity, ensure consistent quality, and of course lower costs. It is difficult if not impossible to attain these goals without accurate real-time and historical weld process information. In the past, some companies have attempted to use “bolt on” equipment to obtain this type of information. Welding power source manufacturers have now begun to incorporate weld process and production management information into their product offering. This discussion will focus on how the information provided by this new generation of power sources can be used to increase productivity, improve quality, reduce costs, and better manage the overall welding operation. Miller’s Axcess power source will be used as an example.

Miller’s Jim Cuhel and Ron Halpenny of Graham Corporation will present “Controlled Short Circuit GMAW Process Competes Favorably with SMAW, GTAW” from 3:05 to 4:00 pm in room N231. Here’s a brief overview:

The combination of Regulated Metal Deposition, or RMD™, and the Pro-Pulse™ Pulsed MIG process Pro Pulse provides an efficient method of welding pipe from root to cap with one wire and one gas. The presentation includes a case study involving Graham Corporation, the world leader in engineered-to-order vacuum and heat transfer equipment. These processes have significantly reduced rework (down from 3.2 to 1.3%) and lead times. This includes faster travel speeds on root passes (between 6 to 12 ipm) and a 22% productivity increase over manual TIG. In summary, the described technology provides the following: it reduces rework on the root pass in pipe welding applications and distortion by reducing overall heat input in pipe welding applications. The need for back-purging in stainless pipe welding applications is also eliminated. Travel speeds are also increased.

We hope you attend some of these valuable presentations. For a glimpse at the entire schedule of educational seminars at FABTECH, click here.

Responsible and Sustainable Fume Management Webinar Archived

Thursday, September 1st, 2011

Did you miss Miller’s webinar on Responsible and Sustainable Fume Management co-sponsored with ISHN? You can still review the whole presentation here.

Here’s a description:

Welding fumes and fume regulations have become an ever increasing area of concern for welding facilities and safety personnel. While there has been a great deal of communication, there are still many questions among occupational health and safety managers as to the most appropriate courses of action in identifying the best suited and sustainable solutions for reducing the possible risks associated with weld fume exposure.

In this webinar, Miller Electric Mfg Co Product Manager Al Hilbert and Product Specialist Eric Sommers along with Hobart Brothers Welding Engineer, Aaron Bischoff will join Peter Lemke, president of The WORCS, and Industrial Hygienist, Bert Schiller to discuss the most relevant regulations and sustainable practices that any weld shops needs to be aware of when deploying a fume control program and choosing the proper controls. This webinar is a must-attend for any company that has welding in their operations.

What you will learn:

  • How regulations can impact your welding operations
  • Sustainable & best management practices for weld fume control
  • What to look for in engineering, administrative and PPE fume solutions