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Archive for the ‘Welding Techniques and Processes’ Category

Stainless Steel Filler Metal and Shielding Gas Selection for Automotive Projects

Tuesday, April 16th, 2013

Ready to tackle that stainless steel project out in the garage? Miller Marketing Manager John Swartz discusses important factors for stainless steel filler metal and shielding gas selection in the video below. Also, follow the link below for a handy stainless steel filler metal selection cheat sheet.

Stainless Steel Filler Metal Selection Chart

Swartfager, RMD, Pulsed MIG and Metal-Cored Wires

Wednesday, February 13th, 2013

Swartfager Welding is the epitome of a family business done right. What started six generations ago in the 1800s as a traditional blacksmith operation has evolved today into a booming modern fabrication business.

We visited Swartfager to discuss with them one of their more successful process advancements: transitioning to metal-cored wires and optimizing these applications with new Pulsed MIG and Regulated Metal Deposition® capabilities as made possible by the PipeWorx multiprocess pipe welding system.

Benefits achieved by Swartfager include increased productivity, less post-weld cleanup, and easier operation and training for its workforce – all while meeting code requirements.

Read the whole story by clicking here.

Hear from Swartfager straight from the shop floor on this and other exciting process improvements:

RMD, Pulsed MIG and Metal-Cored Wires

Repairing Cast Stainless with Dynasty TIG Inverters

Induction Heating at Swartfager Welding

 

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.

Welding Design & Fabrication: Slashing Welding Preheat Time

Thursday, July 12th, 2012

Our friends and Welding Design & Fabrication recently ran with Steve Latvis’ article on induction heating at Topp’s Mechanical in Tecumseh, Neb.

A snippet:

With induction heating Topp’s Mechanical has a solution that exceeds the quality standards of its heat-treatment applications and provides significant operational benefits including:
• Faster time-to-temperature;
• Consistent heating throughout the entire part;
• Easier to apply/wrap heat;
• Greater reliability and lower consumable costs;
• More efficient use of labor; and
• Improved employee safety.

Read the whole story by clicking here!

Then check out these videos:
Induction Heating on P1 Headers

Discussing Induction Heating & the ProHeat 35

Ease of Use

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!

Aluminum TIG Welding with John Marcella of Marcella Manifolds

Thursday, June 7th, 2012

We recently spent some time with John Marcella of Marcella Manifolds. John is known for his impeccable craftsmanship and a keen eye for the appearance of his aluminum welds. In the series of videos below, see John discuss his welding techniques and building custom manifolds for the racing industry.

TIG Welding Aesthetics with the Dynasty 350

Marcella Manifolds & TIG Welding Aluminum Manifolds

Wireless Remote Foot Controls for TIG Welding

Miller Reinvents Bobcat™ Engine-Driven Welder Generators

Monday, April 9th, 2012

Miller has re-engineered its class-leading Bobcat line of engine-driven welder/generators to reduce sound, reduce weight, offer a smaller footprint, reduce fuel use and simplify daily maintenance. Sound on the newly designed Bobcat models is reduced by as much as 33 percent, and the machine is up to 5 inches shorter and 55 pounds lighter (depending on the model). The Electronic Fuel Injection (EFI) option with the Bobcat 250 also reduces fuel use by as much as 27 percent compared to carbureted models.

Engine-driven welder/generators are ideal machines for service trucks and/or emergency power situations on farms and ranches, and are also often found in construction, MRO, and fabrication applications.

The EFI option (Bobcat 250 only) optimizes the air/fuel ratio for less emissions, longer runtimes and superior performance compared to carbureted models. It provides more reliable starting performance in cold climates, requires no choke, and is less prone to fuel deterioration due to infrequent use. Payback can be achieved in a matter of months with up to 27 percent fuel savings.

Each Bobcat engine-driven welder/generator has also been fully optimized for truck integration. The shorter and lighter design allows more room for other tools and equipment, and reduces the wear and strain of a heavier machine on the truck’s chassis. Daily maintenance has also been made easier with front panel displays to help users keep track of service intervals, as well as the intuitive placement of service points. Oil and air filter checks are performed from the top by the front panel, and fuel fill and oil drain/filter are easily accessible on the side. Tool-less panels allow for quick access.

The three new models are:

Bobcat 250

Bobcat 225

Bobcat 3 Phase

Bobcat 250 EFI

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

Graham Reduces Rework, Changeover Time with PipeWorx

Monday, February 20th, 2012

http://youtu.be/PEg9IDxQmkM

The RMD™ and Pro-Pulse™ processes found in PipeWorx contribute significantly to Graham Corporation’s 20 percent reduction in production hours by improving first pass weld quality, eliminating the need to compensate for distortion and reducing set-up and process change-over time.

To read the whole story, click here.

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.