Manufacturing Welding Equipment and Solutions | MillerWelds

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Industrial welding solutions to maximize your productivity

Deltaweld Systems: the new standard in manufacturing. Learn More.
Fume Management Solutions. Own your environment.
FabCO Triple 7 Wires. Good puddle control and less clean up in all positions. Learn more.
Insight Welding Intelligence, Increase your quality, productivity and competitive edge. Learn More.

Empower Every Welder to Meet Your Production Goals

To move your business forward, you need to boost output, minimize costs, and ensure quality and safety — all with welders of varying skill levels. Count on Miller for solutions to workforce challenges: easy-to-use equipment that empowers every welder — and help your business succeed.

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Manufacturing Knowledge Center

Driving Improvements in Automation with Welding Information

In addition to the quality, productivity and cost-savings benefits fixed and flexible welding automation can offer companies, implementing a welding information management system in a robotic weld cell can add to efficiencies and profitability. Production and weld process data, along with weld process features each make an impact.
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7 Questions to Ask Before Purchasing a Welding Information Management Solution

Welding information management solutions can help companies address pain points by offering effective training, increasing productivity, reducing costs, enforcing proper weld sequence and preventing missed welds — among other benefits. Before making the investment, however, it is important to ask some key questions to ensure the best results.
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Do's and Don'ts of Welding Information Management Systems: Tips for Gaining the Best Results

Welding information management systems offer real-time data help companies ensure the use of proper welding parameters, augment training and make it easier to benchmark continuous improvement efforts. To gain the optimal results when using these systems, companies should consider some important do's and don'ts for implementing them.
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How to Drive Improvement with an Existing Welding Power Source Fleet

Utilizing external weld monitoring solutions allows companies to gain insight into quality and productivity metrics on any brand of power source, old or new, so they can drive continuous improvements in their welding operation.
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Advancements in Weld Processes: Benefits and Opportunities

Equipment manufacturers have responded to changes in the industry by introducing more advanced welding processes to help drive improvements and give companies a competitive edge.
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Industry Demands Spark Welding Technology Changes

The fabrication and manufacturing industries are constantly evolving, challenging companies to seek out new technologies to help them stay competitive. From the introduction of new materials to an increased need for welding automation, weld data monitoring and more, changes are driving companies to acquire solutions to help them maintain the highest levels of quality and productivity.
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4 Common Challenges to Address Before Automating the Welding Operation

For first-time users, welding automation can seem intimidating. When making the investment, it is important to plan the purchase carefully and to implement some best practices in order to achieve the best results. Starting out with simple equipment, getting the appropriate buy-in, and analyzing part volume and workflow are all critical.
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Ways to Increase Arc-On Time and Throughput in the Welding Operation

Advanced welding information management systems can help companies increase the time spent welding, but just as importantly, they can also give companies the ability to analyze and reduce downtime, and evaluate non-welding activities. Combined, this functionality can lead to greater efficiencies in the welding operation and the production of more parts in less time.
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First Time Welding Automation User Gains Productivity and Quality Benefits

Kenosha Metal Products, a metal stamping company new to welding automation, added three new jobs, increased productivity and improved weld quality by adding Miller PerformArc™ pre-engineered robotic welding cells to its facility.
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AGCO's Jackson, Minn. Facility Uses Miller Axcess® E with Insight™ to Drive Welding and Fabrication Excellence

Management at AGCO's rapidly expanding Jackson, Minn. manufacturing plant knows that information is key when building the biggest and most innovative machines in farming. With Axcess E with Insight from Miller Electric Mfg. Co., AGCO has a solution that provides information to operators and engineers, allowing them to optimize the welding and fabrication process.
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Easy-To-Use Welding Technology Shortens Welder Training and Reduces Rework

Welding power sources are easier to use, with simplified interfaces and push-button changes. Learn more about new solutions.
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Chandler Equipment Gains Unexpected Benefits from Fume Extractors, Years After Installation

Arkansas-based Chandler Equipment continues to reduce maintenance time and costs with its FILTAIR® centralized fume extractions systems from Miller. Two and a half years have passed since investing in the systems and the company still hasn't needed to change the filters — plus they continue to experience significant fume reduction. 
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Turning Welding Data into Dollars

A welding information management solution can measure and track performance metrics to improve productivity and quality — making an overall positive impact on your bottom line. Accurate, real-time data collection and analysis can provide a benchmark for measuring the impact of improvements, and the right technology helps you turn that data into dollars.
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Advances in Aluminum Robotic Welding

Aluminum presents several challenges during the welding process, such as burn-through, warping or lack of fusion. Learn about robotic welding systems.
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Robotic Welding Can Offer Benefits for Smaller Shops

Welding automation is no longer just for large manufacturers. Increasingly, smaller shops are taking advantage of the productivity, quality and cost-saving benefits of implementing a robotic system. Gaining the most out of welding automation, however, isn't a matter of chance. Careful planning and a keen attention to detail both play a role.
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Should Your Welding Operation Switch to Laser Keyhole Welding?

A change from resistance spot welding to laser keyhole welding can provide significant benefits in some manufacturing operations.
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Reducing Risk When Investing in Welding Automation: Five Steps to Success

Welding automation can provide companies with competitive advantages by making them more productive and by generating higher weld quality. The technology can also improve their profitability. To gain the best success and reduce the risk in the investment, it’s important to follow some best practices when implementing a robotic welding system.
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The Real Cost of Missed or Defective Welds

The goal of any welding operation is to create quality products for customers, while also managing costs and maintaining the desired levels of productivity. Missed or defective welds can have a negative impact on a welding operation, leading to potential safety issues and a loss of revenue for addressing failures or liability claims. Detecting those problems early in the welding operation is vital...
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Breaking through the Bottlenecks: Going Lean in the Welding Operation

When implemented correctly, lean practices in the welding operation can help companies expand their capacity without expanding their facility or workforce.
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Aluminations (4): Shedding Light on Aluminum Welding Issues

Is spray transfer too hot? Short circuit too cold? Then consider Pulsed MIG for aluminum. It can combat warpage, burn through, lack of puddle control, lack of fusion, spatter and poor appearance. This Aluminations explains the pulsed process and introduces a simple, affordable machine with built-in pulsing controls.
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Pulsed MIG Welders from Miller Pay for Themselves in Six Months for Pump Manufacturer

Weir found that using the XMT® 304s not only saved money in energy and consumables - paying back the cost of the equipment in 6 months - but also increased productivity, cut maintenance costs and improved weld quality for operators at all levels thanks to the easy-to-use controls and built-in programs. In fact, in a head-to-head test, the XMT 304s demonstrated that they perform 22 percent faster,...
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Tips for Troubleshooting Common MIG Weld Defects

Weld defects are often caused by improper technique or parameters, such as poor shielding gas coverage or incorrect travel speeds.
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Optimize Robotic Welding Cells by Reducing Secondary Circuit Wear

Learn more about robotic welding cell best practices — and secondary circuit technology — that keep operations optimized.
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Iowa-Based Manufacturer Sees Safety and Productivity Benefits with Miller Fume Extraction Technology

Among the guiding philosophies at Vermeer is the belief that the company's employees are its most important resource, helping to deliver on the commitment to improve productivity and profitability for its customers with equipment that meets their needs.
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Addressing the Welder Shortage with Technology

There are welding technologies and solutions that can help companies find and train skilled welders faster — and make it easier for welders to complete high-quality welds once they are on the job.
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Tips to Optimize the Robotic Weld Cell

Proper layout in a robotic welding cell can significantly improve success in the operation, allowing companies to gain productivity and improve quality.
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Is Laser Welding a Good Fit for Your Operation?

For companies looking to improve productivity and reduce costs in the welding operation, laser welding is one option to consider. Laser welding is more accessible and affordable than ever — offering much faster travel speeds than other welding processes and weld consistency in automated welding applications.
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From Basic to Advanced: Wire Feeders Impact Quality and Productivity

Having the right wire feeder for the job can play an important role in reducing unnecessary downtime for addressing issues associated with poor wire feeding. Options include basic, intermediate and advanced wire feeders.
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An Introduction to Pulsed GMAW

Pulsed gas metal arc welding (GMAW) can offer companies quality and productivity advantages, including for welding operators of varying skill levels. In some cases, companies may be hesitant to adopt the process, but it can offer distinct advantages.
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Aluminations (2): Shedding Light on Aluminum Welding Issues

This issue of Aluminations discusses important topics related to welding thin aluminum, including advanced AC TIG controls, tungsten preparation and machine selection.
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Top 10 Mistakes in Running a Welding Operation and Simple Ways to Solve Them

With so many factors to monitor — equipment, weld procedures, filler metals and consumables — it's inevitable that mistakes will occur in most welding operations on any given day. Human error dictates that a welding operator can easily set a power source and wire feeder to the wrong parameters or trim and install a MIG gun liner improperly. But there are other mistakes that can occur in welding...
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Pulsed MIG May Solve Aluminum Fabrication Problems -- Q&A

Questions and answers for Pulsed MIG aluminum welding.
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Understanding Key Welding Business Issues And Turning Them into Opportunities

In surveys conducted by Miller Electric Mfg. Co., fabricators, manufacturers and contractors consistently report that their most important welding-related issues are the need to reduce welding costs, improve productivity, address the welder shortage, find ways to justify new equipment, and simplify the welding process. This article discusses these issues and links you to examples of companies that...
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Aluminations (5): Shedding Light on Aluminum Welding Issues

When you control the shape of an AC TIG weld bead, you control profitability. The perfect bead takes less time to weld and looks great without grinding or polishing. This Aluminations explains how balance control and output frequency affect penetration depth, bead width, etched zones - and your bottom line.
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Aluminations (3): Shedding Light on Aluminum Welding Issues

Burnback. Wire stubbing. Porosity. Erratic feeding. These common problems plague fabricators that MIG weld aluminum. Often, they result from an inadequate or improperly adjusted wire feeder system. If you want to gain more control over MIG aluminum productivity, this Aluminations provides troubleshooting tips and introduces new push-pull feeder technology.
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Marine Hardware Manufacturer Reduces Welding Rework on Anodized Aluminum

G.G. Schmitt & Sons saves time and money with Dynasty® 400 TIG welders, cutting hours of rework on some parts.
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Truck Manufacturer Improves Aluminum MIG Welding With XR Wire Feed Systems

The leading manufacturer of aluminum vehicles increases its competitive edge with the new XR-Edge feeder system.
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Pulsed MIG Welding Increases Productivity, Reduces Distortion and Cleanup for Specialty Sports Equipment Fabricator

Transition from spool gun to all-in-one MIG system with synergic Pulsed MIG capabilities increases travel speeds, reduces birdsnesting, spatter, time associated with switching out spools and provides greater accessibility to tight spots.
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Bring the Heat to Avoid Six Common Welding Errors

Mistakes can have a big impact on the bottom line in manufacturing welding operations. While these common mistakes may seem minor, they can cause significant problems.
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Say Good-Bye to Burn-Through: New Pulsed Welding Technology Solves Problems Common to Welding Sheet Metal

If you weld sheet metal and use conventional welding equipment, there's a good chance you have a great opportunity: use new Pulsed MIG and TIG technology to improve first-pass yield rates, lower cycle times and reduce piece costs.
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Considerations for Switching to Pulsed MIG and Pulsed TIG Welding in Thin Gauge Aluminum Applications

If you're currently experiencing burn-through, warping, rework, bead profile issues, or problems with arc starts and stops, modern welding technologies with advanced pulsed welding abilities may provide advantages worth investigating.
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How to Successfully MIG Weld Aluminum [Guide]

MIG welding aluminum can be difficult, as it is very different from MIG welding mild steel. Follow this guide to learn the key factors to consider.
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MIG Welding Aluminum: Important Questions and Best Practices

Experts from Miller Electric Mfg. Co. discuss important questions regarding MIG welding aluminum, and how you can get the best performance out of your MIG system.
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Reach Your Welding Automation Goals With Advanced Processes

Implementing advanced welding processes featured on power sources already in use — or investing in newer machines with these capabilities — can help companies take their automated welding operation to the next level.
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Boilermakers Local 92 Changes Training Processes to Meet Labor Demand

Boilermakers Local 92 in Bloomington, California, is experiencing significant growth in labor demand, caused in part by a recently enacted state law that impacts refinery jobs.
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Next Generation Welding Helmets Offer Benefits for Operator Comfort and Productivity

Having the best possible helmet for the job can reduce workplace injuries and discomfort — and allows an operator to weld for longer.
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Reduce Weld Fume Exposure by Choosing the Right Option

Protecting employees against weld fumes is critical to providing a safe working environment. Choosing the right weld fume management solutions can also have a positive impact on the bottom line through improved productivity.
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Pulsed MIG Improves Aluminum Welding Performance

When MIG welding aluminum, obtaining good quality and productivity depends on using the right welding process and system. This may seem like common sense, but many fabricators get hung up on purchase price vs. life cycle costs, or they try to weld aluminum with the same processes and systems used for steel. The newest generation of pulsed MIG welding systems addresses these issues. Even better,...
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How to Choose MIG Welding Consumables to Optimize Productivity

Labor is 85 percent of a welding operation’s costs. Learn how the right consumables can improve productivity and minimize downtime.
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New Welding Processes, Technologies and Retraining Help Address Labor Shortage

Learn how to increase productivity of the welding operation through new technology and advanced processes.
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Updating Your Aging Welding Equipment can Drastically Improve Quality, Productivity - and Often a Quick ROI

What was state-of-the-art 10 years ago may bear little resemblance to today's equipment and the advantages it offers. Today's welding power sources provide many benefits that can help shorten prep time, increase deposition rates, decrease training time, and/or reduce weld defects and rework time. In addition, today's power sources, especially inverters, offer increased power efficiency, which alon...
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New Welding Equipment Helps Business Drive Forward

Investing in new welding technology can often help companies improve their business and the bottom line. For Wilcox Commercial Vehicle, an aluminum body builder for commercial vehicles, new inverter power sources proved to be cleaner, faster and more efficient for welding aluminum.
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Fan Manufacturer Standardizes on Pulsed MIG Welding for Aluminum

Pulsed MIG improves productivity, reduces reject rates and provides Greenheck with welding versatility not possible with older technology.
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Defense Fabricator Lands New M-ATV Contract With Pulsed MIG Welding Fleet, Impeccable Accountability and Quality

Welding MIL-A 46100 ballistic steel for armored military vehicles isn't something that any local fabricator can tackle. Ultra Machine and Fabrication has spent 21 years meticulously building its fleet of fabricating equipment to serve the armoring needs of defense contractors and the U.S. military. When new contracts began specifying Pulsed MIG welding using a 307 stainless steel filler wire, Ultr...
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Pulsed MIG Welding on Aluminum: The Details and Advantages

Aluminum has been and continues to be a staple in industries ranging from aerospace to shipbuilding, as well as trailer fabrication. Its corrosion resistance and strength are both assets that make it desirable for applications encountering moisture and/or those requiring lighter weights. 
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Aluminum Jet Boat Manufacturer Turns to Pulsed MIG to Keep Boat Production at Full Throttle

Smoky Mountain Jet Boats is known as a top-line manufacturer of aluminum jet boats that thrill riders in water as shallow as 4 inches. The boats are made to Coast Guard specs but wouldn't be profitable or even possible without Pulsed MIG welding.
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Tech Talk: Advancing Technology For Simplicity, Productivity

An insider look into some of the advanced welding technologies and advances put forth by Miller Electric Mfg. Co.
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What You Need to Know About Cleaning and Preparing Aluminum Filler and Base Metals Before Welding

Dirty aluminum sets you off on the wrong foot before you ever strike an arc. Take these cleaning/prep steps for the optimal welding of aluminum.
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The Ergonomics of Welding Shop Design

In creating a smooth-running, functional and efficient welding lab, time spent beforehand is well worth the investment"...So is choosing the right welding equipment, which can decrease energy costs, increase space and provide arc quality that promotes learning.
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Translate Welding Benefits into Bottom-Line Dollars to Justify Equipment Acquisition Costs

Learning to speak the "financial language" of those responsible for your company's profits and losses can help you justify the purchase of new welding equipment. Measuring improvement through proven formulas for return on investment (ROI) and payback, as well as documenting potential productivity increases and efficiencies, can go a long way in making new equipment purchases a reality.
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The Business of Weld Fume: Ways to Create a Safer Work Environment

The goal of any company, beyond its productivity and profitability, is to help maintain a safe and comfortable work environment for its employees. Making the decision to implement process changes and technologies that reduce weld fume can lead to greater productivity, better weld quality and a better bottom line. The question becomes a matter of what type of filler metal, welding process and fume...
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The Most Common MIG Weld Defects on Aluminum and Steel and How to Avoid Them

This article describes some of the most common MIG welding defects, such as porosity, lack of fusion and burn through and how to identify them by weld bead appearance.
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Smarter Solutions to Welder Heat Stress: Keeping Workers Comfortable, Safe and Productive

With numerous studies pointing to heat's negative impact on performance, fabricators are naturally searching for technologies that offer a combination of convenience and results. Miller's CoolBand™ and CoolBelt™ are solutions that have been shown to reduce temperatures significantly with minimal extra weight or feeling cumbersome to the welder. At a price of $150 and $295, respectively, they also...
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Small Wisconsin Fabricator Assists With Critical Defense Department Jobs Using Miller Equipment

Performance Welding's fabricators rely on the XMT® Series of multiprocess inverters from Miller Electric Mfg. Co. to fabricate protective fins for armored personnel carriers (APCs). Currently they use three XMT® 304 CC/CV machines and one new XMT 350 CC/CV inverter featuring Auto-Line™ primary power management technology.
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The Right Filter Makes a Difference in Weld Fume Management

Choosing the appropriate filter media can help increase productivity and profitability by lowering downtime, improving airflow and reducing filter replacement costs.
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Navigating OSHA's Hierarchy of Controls to Minimize Weld Fume

Protecting employees against weld fumes is as much a matter of creating a safe and clean work environment as it is giving companies a competitive advantage to attract and retain skilled welding operators. The Occupational Safety and Health Administration outlines steps for weld fume management in its Hierarchy of Controls to help companies improve workplace safety and compliance.
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Empower Your New Welders

Operations can empower new welders with solutions that help them more easily produce quality welds and get into production faster.

Insight Pipe and Vessel Solution from Miller Tracks Weld Data, Improves Productivity

As part of our Welding Intelligence™ solutions, Miller has expanded its welding information management software to the PipeWorx 400 Welding System.

Maximize Your Welding Productivity

Stay ahead of welding challenges with the right solutions from Miller, Bernard and Hobart Filler Metals.

Jetline Seam Trackers Simplify Welding and Improve Quality

See the Jetline® Tactile Seam Tracker system in action as it consistently positions the weld head for optimal arc performance.

How to Replace Your MDX™ MIG Gun’s Handle, Switch and Neck

Learn how to replace the handle, switch or neck on your MDX-100 or MDX-250 MIG gun.

How to Change Consumables on Your MDX™ MIG Gun

Learn how to change the nozzle, contact tip, gas diffuser or liner on your MDX-100 or MDX-250 MIG gun.

How to Reinstall a Trimmed Liner in Your MDX™ MIG Gun

Learn how to reinstall a trimmed liner in your MDX-100 or MDX-250 MIG gun.

Quick Tip: When to Choose Welding Automation

Do you have parts that are highly repeatable, in high volumes with good fit-up? If yes, automation might be a good fit for you.

Gain the Best Submerged Arc Welding Performance with the Right Flux

Hobart fluxes do more than protect the weld — they are formulated to meet your exact submerged arc welding needs.  

Control your heat input with innovative Miller SubArc solution

With the Miller SubArc Digital Series, both CV and CV+C weld modes come standard on the SubArc Digital Interface.

Submerged Arc Welding Can Greatly Improve Deposition Rates

The Submerged Arc Welding (SAW) process offers a number of advantages — primarily the high deposition rate that can be achieved.

MIG Welding Basics: What is Spray Arc Transfer?

Learn how spray transfer in MIG welding works and is especially beneficial for welding heavy plate and in high-volume manufacturing.

MIG Welding Basics: What is Short Circuit Transfer?

Learn how short circuit transfer in MIG welding works, and its advantages on thin materials.

Preventing Porosity in Aluminum Welding

Tony Anderson, director of aluminum technology, discusses the causes of porosity when welding aluminum.

ZoneFlow Fume Extraction Technology: Wide Fume Capture Zone

Get a weld fume capture zone that’s up to three times larger than traditional fume extraction systems.

Advancements in Hobart Self-Shielded Wires Benefit Transmission Pipeline Applications

New Welding Technology Increases Manufacturing Productivity

Today’s welding technology can help companies increase productivity and quality, even when faced with a shortage of welding operators and new materials, such as high-strength steels.

Optimize Results with Multiple Torch Configurations for Submerged Arc Welding System

Multiple torch configurations for a Submerged Arc welding system provide flexibility to best optimize results for your operation.

Pulsing with TIG

Miller Welding Engineer Zack Erndt explains the benefits of using pulse when TIG welding and talks about applications where low and high pulses per second can be used.

Solutions to Improve Aluminum Weld Quality and Strength

Miller and Hobart offer equipment and filler metal solutions to improve aluminum weld quality, and are showcasing these products at FABTECH 2015.

Top Five Reasons to Consider Pulsed MIG Welding

Pulsed MIG welding provides a number of key advantages in welding applications. Jim Wynegar shares 5 reasons to consider Pulsed MIG welding in your operations.

Miller Explains Globular Transfer in MIG Welding

Learn about what globular transfer in MIG welding is and why it occurs in this video from Miller.

Selecting the Right Gun for Aluminum Welding

Guns designed specifically for aluminum welding are capable of feeding the soft wire, while also minimizing wire-feeding problems such as bird-nesting.

Feeder Options Can Help Reduce Jobsite Clutter

Welding operators may question whether the equipment needed for wire processes is durable enough for the field environment.

Pulsed MIG Welding and Metal-Cored Wire Give Bell Steel Contract-Winning Edge

Electroslag Strip Cladding Offers Productivity and Cost Benefits

Submerged Arc Strip Cladding (SASC) and Electroslag Strip Cladding (ESSC) are similar types of Strip Cladding.