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Off-Road Warriors: Camburg Engineering Does it All

Monday, June 23rd, 2014

Camburg_0958_480

With a shop of over 10,000 square feet, Camburg Engineering is a leader in off-road suspension systems and one of only a few companies with the manufacturing capabilities to both produce their own suspension components in-house as well as build their Kinetik race trucks from the ground up.

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Watch Feature Video

Watch How-To Videos:
Lower Control Arm Assembly for ’96 – ’04 Toyota Tacoma and ’00 – ’05 Toyota Tundra

Welding Rear Suspension Pivot Box for Camburg Kinetik Series Trophy Truck

NEW Women’s Arc Armor® Welding Protection Designed for Superior Fit and Productivity

Thursday, January 2nd, 2014

Miller recently launched new women’s Arc Armor®apparel, including the INDURA® cloth jacket and MIG and TIG gloves. Specifically engineered with feedback from women welders, the new apparel provides superior fit and comfort for elevated performance.

Made from INDURA flame-resistant cotton, the women’s jacket provides less restriction for better movement and increases safety with a tailored fit.

The new women’s MIG and TIG gloves, now available in X-Small and Small, are part of an overall Arc Armor glove redesign. The smaller sizes ensure welders have a glove option that fits their needs while providing the best welding protection available.

Women’s MIG Glove (lined)

• Dual padded palm for added comfort

• Fleece insulated palm, foam insulated back

• Original wrap-around keystone thumb design for exceptional dexterity and comfort

Women’s TIG Glove

• Unlined for heightened feel and dexterity

• Triple padded palm for added comfort

• Premium goat grain leather offers superior flexibility and dexterity

For more information on the Miller Arc Armor line of welding protection, visitMillerWelds.com/arcarmor.

Best Practices for Tungsten Preparation

Thursday, December 5th, 2013

A clean, well-prepared tungsten of good quality is absolutely essential to the proper performance of your TIG set-up.

Tungsten Grind 2With inverter machines in both AC and DC polarities, your 2% Ceriated or 2% Lanthanated electrode should be ground to a point with an included angle between 15 and 30 degrees, then the tip blunted slightly. If the tip is left as a fine point, there will be a much higher likelihood of tungsten inclusions, as the point can melt off into the weld pool.

 

Always grind your electrode along the axis, never perpendicular to the axis. When the grind marks go around the tip instead of along it, the arc will be more likely to wander as it tries to follow those minute grooves. Be sure to use a grinding wheel — preferably diamond and never aluminum oxide — dedicated to tungsten sharpening to avoid cross contamination from other metals.

Tungsten Grind 1

 

If your electrode is dipped into the weld pool, never grind through the contamination because it may get loaded onto the wheel and deposited right back onto your electrode whenever you rework it. Also, never break off a contaminated tip. Instead, it should be cleanly cut off with an abrasive wheel to prevent the small cracks that result from fracturing. These cracks can wreak havoc on the electrode’s performance.

Taking care of the small details can have a significant effect on your welding success!

Devan DePauw

Welding Engineer

TIG Solutions

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

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

Tips for TIG welding an upper control arm

Thursday, April 11th, 2013

Buzz Johns, head fabricator at ThorSport Racing, explains how to fabricate an upper control arm. Watch this two-part series for a step-by-step process and tips for keeping weld distortion to a minimum.

Part one:

http://www.youtube.com/watch?v=2UDfxGK1Jt4

Part two:

http://www.youtube.com/watch?v=AKJgO-Y5NX4

Using Pulse Variables

Monday, March 4th, 2013

When utilizing the pulse feature on the Miller Maxstar or Dynasty products, there are several variables to adjust that can yield significant benefits. With the proper settings of these variables, the pulse feature can increase weld quality, weld penetration, and travel speed – all of which translate into increased productivity. The three variables are:

  1. Pulses Per Second [PPS] (the number of times the machine switches from a high to low amperage each second)
  2. Peak Time [Peak t] (percent of the pulse cycle spent in the high amperage)
  3. Background Amperage [BKGND A] (low amperage as a percent of the peak amperage).

A good starting point for these variables is 120 hz, 40%, and 25% respectively.

Adjusting the PPS provides the most visible change to the weld operator. Increasing this frequency will tighten the arc cone which can result in better directional control, a smaller weld puddle, and increased penetration.

Andrew Pfaller
TIG Solutions Product Manager/Weld Engineer

Think about weld penetration

Monday, January 7th, 2013

When welding thick to thin or thinner material, concentrate or point the gun more at the thicker material and roll the bead toward the thinner material. This will help with adequate penetration on both the thick and thin piece. Take precautions to prevent warpage. When welding thin material, you may want to place a thicker piece of copper or aluminum behind the weld area to help “sink” the heat away (which prevents warping). This also will help with burn-through. Keep in mind that if you are welding on a table, you’ll want to get one with a thick metal top. A top with a ¼-in steel plate or thicker will not warp while you are welding on it. Do not place a metal plate on top of a wooden table. It will still burn the wood. I know it sounds like common sense, but it happens….

Until next time,

Andy Weyenberg
Motorsports Marketing Manager

Picking the right consumable

Thursday, November 15th, 2012

Consumable matching is key when welding. If you are running .030 wires in your MIG welder, make sure the liner, drive rolls and contact tips match. Any mismatch will cause feeding and weld consistency problems. It’s also important to pick the right wire size for the job. Don’t use .035 wire to weld 22 gauge steel. As a rule of thumb, the wire shouldn’t be bigger than the material thickness. If it is, you’ll spend most of your time blowing holes in the base metal instead of melting the weld wire.

Gas is technically a material, too, so determine the correct mix before beginning. Miller offers some tips on consumables here. For MIG steel, a 75/25 argon/CO2 mix will give great results. Straight CO2 can also be used to get more penetration, but this gas will also produce more spatter. Typical flow rates are 25-30 CFH. Too high of flow will cause turbulence and contamination. Too low flow will not give enough shielding of the weld area and also produce porosity of the weld bead. For all TIG processes and MIG aluminum, 100 percent argon gas is typically used. Flow rate will depend on cup size with most flow rates being near 12-20.

Until next time,

Andy Weyenberg
Motorsports Marketing Manager

Stephen Christena and Tom Patsis Fabricate Metal Art at SEMA 2012

Friday, November 2nd, 2012

Stephen Christena of Midwest Metal Works and Tom Patsis of Cold Hard Art fabricated unique pieces of metal art in the Miller booth at SEMA. On Tuesday and Wednesday, Stephen fabricated Cam Shaft Cocktail Tables out of automotive parts:

On Thursday and Friday, Tom Patsis fabricated Hem-me Spyders. All of the metal art was included in the SEMA Cares Silent Auction, as well as a “Trashformer” that was fabricated using automotive parts by Patsis pre-show: