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Optimized Welding System Simplifies Aluminum Auto Body Repairs

Tuesday, April 7th, 2015

The new Millermatic® 350P auto body aluminum repair system is a complete welding package designed to provide high weld quality and simplify repairs on aluminum auto body panels and beds, such as found in the 2015 Ford F-150 truck. This turnkey soMM350P_158x102lution addresses the growing trend of aluminum usage in the automotive market and has been designed to address challenges posed by welding thin gauge aluminum, such as warping, distortion and burn-through.

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Avoiding porosity when welding aluminum

Tuesday, June 18th, 2013

Porosity is a common problem when welding aluminum that has not been properly prepared. It is often caused by the presence of trapped contaminants in the porous layer of aluminum oxide on the metal’s surface. For the best results, this layer and any associated contamination must be removed prior to welding.  This can be done in three simple steps:

  1. Degrease: Use acetone or denatured alcohol and a lint free rag to remove any hydrocarbons and moisture that may be present on the surface.
  2. Mechanically remove the oxide: This can be accomplished by scraping, cutting or milling without cutting fluids or by using a clean stainless steel brush. (Never use an abrasive. Most are made from aluminum oxide itself and all can leave foreign material imbedded in your base metal)
  3. Degrease again: Repeating the process of step 1 will take care of any remaining oils that may be present.

*ALWAYS store flammable substances safely away from the weld zone and be certain any degreasing agents have fully evaporated from the workpiece before you begin welding.

*NEVER use any cleaners or degreasers that contain chlorine or chlorinated hydrocarbons in or near your weld zone. Harmful chemical compounds can be released when such cleaners are used in conjunction with welding processes.

Devan DePauw

Welding Engineer

TIG Solutions

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

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

Considerations for Switching to Pulsed MIG and Pulsed TIG Welding in Thin Gauge Aluminum Applications

Tuesday, February 28th, 2012

Pulsed welding equipment has been around for a long time. However, technical advancements have made pulsed welding equipment much easier to use and, consequently, better for training operators to make quality welds. Some of the new Pulsed MIG and Pulsed TIG welding technologies provide excellent welding performance on thin gauge aluminum.

Upgrading to modern Pulsed MIG or Pulsed TIG inverter technology could potentially help you increase productivity, improve weld quality, reduce weld costs, and boost operator efficiency. That being said, you will need to study your particular application in detail to determine which, if any, of these processes is appropriate for you. Remember, pulse welding is not the answer to all aluminum welding-related problems.

Read the whole article here.

Case Study: Bollinger Shipyards and the AlumaFeed System

Friday, June 3rd, 2011

You’ll be hearing a lot from us over the next few months on aluminum. One of the first things we’d like to share with you is this great snapshot of the aluminum welding needs at Bollinger Shipyards in Lockport, La.

Read the whole story here. After the excerpt, see what the folks at Bollinger Shipyards had to say about Miller’s AlumaFeed™ System.

Aluminum is increasingly specified in marine applications because it’s lighter without sacrificing strength and functionality. This makes ships faster, saves on fuel, and provides them with excellent anti-corrosive properties. It does, however, present difficulties: distortion, cleanliness, aesthetics, burn through and difficult wire feeding, to name a few.

To best meet these challenges, Bollinger overhauled its entire aluminum welding facility to include a new bulk gas delivery system, wall-mounted booms for wire feeders, and new AlumaFeed™ synergic aluminum welding systems from Miller Electric Mfg. Co. The system is designed to simplify and improve MIG and Pulsed MIG aluminum welding applications and has proven a good fit at Bollinger.

Improvements include: Hours saved in productivity, thanks to the synergic controls; reduced distortion and burn through, thanks to the Pulsed MIG capabilities; the aesthetics of a TIG weld with the production speeds of MIG welding; less bird nesting, thanks to advanced wire feeding technology; switch to a larger diameter wire, which allows for faster travel speeds.


New Aluminum MIG Push-Pull Feeders

Wednesday, June 9th, 2010

Building on the proven reliability and performance of our XR Control aluminum MIG push-pull wire feeder, Miller introduces two new models, the XR-S Control and XR-D Control, designed to meet the specific needs of basic and more advanced aluminum MIG applications.

Featuring adjustable run-in, jog & purge, a digital wire feed speed display and the option of using pre- and post-flow, the XR-S Control feeder meets the needs of basic aluminum MIG push-pull applications without all the bells and whistles that aren’t needed & that might lead to inconsistencies between operators.

Taking things a step further, the XR-D Control features point-of-use remote voltage control, digital voltage display, programmable pre- and post-flow, and adjustable start and crater settings.

Check out the XR-S & XR-D news release for more information about the features and benefits of these new products as well as the applications and industries they are designed to serve.

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.