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Archive for the ‘Welding Techniques and Processes’ Category

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.

Top 10 Mistakes in Running a Welding Operation and Simple Ways to Solve Them

Wednesday, August 24th, 2011

Running a welding business/department isn’t easy – we’ve compiled 10 of the most common pitfalls people make and easy ways to avoid them in this article.

Here’s the top 5 – check out the article for the rest:

1: Improper filler metal storage

2: Repurposing old equipment

3: Using the wrong sized MIG gun

4: Improper preheat or interpass temperature control

5: Ignoring preventative maintenance

Manufacturer Succeeds on Aluminum with Pulsed MIG Welding

Monday, August 15th, 2011

Check out one of our latest case studies on Greenheck Fan, a Wisconsin manufacturer who has experienced a number of welding efficiencies by relying on Pulsed MIG for welding aluminum:

As customer demand drove the company to shift much of its product to be fabricated of aluminum (lightweight, aesthetic versatility), Greenheck addressed the need to optimize its aluminum welding applications while maintaining the ability to weld mild, stainless and galvanized steels effectively. The solution: an advanced Pulsed MIG welding system (Miller’s Invision™ MPa Plus System) that not only improved weld quality, but due to built-in efficiencies, also helped the company streamline its welding operations. Improvements include:

  1. Improved welding of thinner aluminum (reduced burn-through, blistering, reduced distortion).
  2. Improved productivity (faster travel speeds).
  3. Improved starts and stops to the weld (ensures quality).
  4. Standardizing on a larger diameter wire (greater deposition, lower cost per pound, simplification of inventory and equipment outlay).
  5. Dual wire feeder makes it fast and easy to switch between types of filler metal.
  6. Improved weld aesthetics compared to conventional MIG welding on aluminum.

Read the whole story here. Check out videos from our visit with Greenheck below.

Advantages of Pulsed MIG welding on aluminum:

Simplified Welding Operation at Greenheck Fan:

Miller’s Introduces New XMT® 450 MPa Multiprocess Welder

Tuesday, June 21st, 2011

Miller is excited to announce today the introduction of the new XMT® 450 MPa multiprocess welder. This new machine offers one of the industry’s most powerful and consistent options for Pulsed MIG welding. It features increased power and duty cycle ideal for heavy carbon arc gouging and large diameter welding applications. It is also optimized for MIG, Stick, TIG, and Flux Cored welding processes.

This powerful new inverter-based power source features the reliability and arc performance of the XMT 350 MPa but with more amperage, exceptional power efficiency and additional programs for Pulsed MIG welding with up to .052- and 1/16-inch wires.

For more information:

To view the product page, please click here.

To read the entire news release, please click here.


Introducing Miller Welding Automation

Tuesday, November 2nd, 2010

We kicked off FABTECH today with a major announcement that introduces a new strategic partnership with Panasonic Welding Systems and the creation of Miller Welding Automation, a new Miller business unit.

This strategic partnership makes Miller Welding Automation the distribution route for Panasonic robotic welding arms in North America. The welding arms will be combined with Miller products and delivered to the market as part of a complete automated welding system. As part of this transaction, Miller has purchased assets of the Panasonic Factory Solutions Company of America (PFSA) welding automation business.

Watch a video of Miller Welding Automation leaders discussing the new strategic partnership or check out our new Welding Automation page for the press release and brochure.

Spectrum 875 Auto-Line Unveiled!

Wednesday, August 18th, 2010

We’re excited to announce the introduction of the new Spectrum 875 Auto-Line plasma cutter to our product line up. Featuring the ability to connect the unit to any input voltage from 208 to 575 volts without the need for any physical linking mechanism, the Spectrum 875 Auto-Line provides convenience and versatility in field applications using either generator or “wall” power.

The Auto-Line feature also allows the unit to seamlessly recognize and respond to power fluctuations due to brownouts or the heavy loads from other machinery without any fluctuations in cutting performance.

And for those who want to take their cutting precision to the next level, an optional machine torch package is available that allows the unit to be hooked up to a variety of automated cutting systems.

Check out the news release and product page for complete details.

Wondering If Advanced Pulsed-MIG Is Right For You?

Thursday, July 15th, 2010

For Ultra Machine and Fabrication (Shelby, N.C.), investing in advanced Pulsed MIG technology was a critical step in positioning the company to win a major contract to provide over 74,000 components for M-ATVs to an Israeli defense firm.

The vehicles are similar to the MRAP (mine resistant ambush protected) vehicles used by the U.S. military, and require the utmost quality from their welds in order to be effective at protecting their occupants from road-side attacks and improvised explosive devices.

The contract called for Ultra to be able to weld MIL-A 46100 ballistic steel in all positions with a 307 stainless steel filler metal, and using the Accu-Pulse™ Pulsed MIG technology in Miller’s Axcess® “multi-MIG” systems, the company was able to produce those components with only 23 defects — a rate of .03 percent.

Click here to read the full story about the challenges Ultra Machine and Fabrication faced in meeting the welding demands for the M-ATV contract and how the Axcess’ Accu-Pulse technology helped the company successfully complete the project and positioned it to win more in the future.

The Proof Is In The Bead: Pulsed TIG for Stainless Steel

Thursday, June 10th, 2010

Wondering if upgrading to Pulsed TIG for your stainless steel applications will net your company any tangible benefits? Then look no further than the test results of a recently completed comparison between standard TIG and four different pulsing programs.

In short, pulsed TIG yielded a 52 percent narrower bead width,  34 percent increased penetration, 60 percent lower heat input, 35 percent faster travel speeds and better overall weld quality!

Need more proof? Check out the full test details along with an explanation of how to select the optimal pulsed program for your application.

Choosing the right TIG welder

Tuesday, May 25th, 2010

Wondering if an upgrade to an inverter-based TIG power source is worth it? Check out this article to read about the experiences of five manufacturers and two schools and the productivity and weld quality improvements they realized by making the switch to inverter-based controls for aluminum, stainless steel and carbon steel applications.

As an example, A1A Dock Products, a small manufacturer of aluminum ladders in Hollywood, Fla., achieved an annual savings of $28,224 by investing in inverter-based TIG power sources. Their investment paid for itself in just two weeks!

But that’s just the beginning. Click here to see what advanced TIG controls can do for you.

The Art of Field Welding Repair

Tuesday, May 11th, 2010

The temptation, when stuck in the middle of a job site with unbearable heat and a tight deadline, may be just to throw a quick weld on a piece of twisted metal and hope for the best. Hope it gets you through the day. But maybe you didn’t properly prepare the joint? Did you cut out the failed material or did you just pile on filler metal, hoping for the best? Do you have the right equipment?

As with most things in life, taking the time to address the situation properly, right now, will prevent future problems/failures.

We’ve put together a number of resources for you over the years on the topic of field welding repair. Bookmark this and come back to it next time you’ve got a repair to make on a crucial piece of equipment.

1. Comprehensive article focusing on field repair for construction equipment

2. Five tips for field repair

3. Selecting an engine-driven welder generator for your service truck

4. Selecting portable welding and plasma cutting equipment for maintenance and repair

5. Evaluating gas engine drives for generator power

Have any field repair horror stories or successes to share? As always, we’d love to hear about it in the comments section.