Welding best practices to improve and track productivity
The welding industry outlook remains strong in many sectors, but a continued shortage of skilled labor is a key challenge for many operations. This challenge may affect their ability to meet deadlines and take on new projects.
There are two ways to address the lack of skilled welders: Recruit and train more welders into the trade and be more efficient with the workforce already on the jobsite. Following some key welding best practices in the field and utilizing the right technologies can help optimize efficiency and reduce weld defects — so projects can be completed faster and more jobs can be taken on.
Tip No. 1: Make adjustments remotely
On structural jobsites, welders may need to make frequent adjustments to welding parameters to get the best results. When the welder must leave the weld joint and walk to the power source to make changes, these trips can add up to several hours of wasted work time every day while also increasing the risk of injury. With updated technology, welders can now adjust settings remotely, significantly reducing the time wasted walking to the power source.
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Eliminate walking to the power source: ArcReach® technology from Miller allows operators to make adjustments at the weld joint using the wire feeder or the remote without the need for a control cable, so they don’t have to walk to the power source to make changes. On some cluttered jobsites, this technology could save 200 to 300 feet of walking down ladders and stairs.
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Control the front panel remotely: Another remote welding technology from Miller is Wireless Interface Control, optional on Big Blue® and Trailblazer® 330 engine-driven welders. Wireless Interface Control gives welders full front panel control in the palm of their hand plus the ability to turn the machine on and off remotely, reducing fuel usage. This eliminates the need to go back to the machine to make adjustments while also extending the time between fuel fill-ups and maintenance intervals.
Tip No. 2: Eliminate cable length voltage drops
One common issue on the jobsite is addressing the voltage drop that can occur in weld cables. Voltage drops happen due to resistance in the weld circuit, which is caused by distance, number of connections and connections that are corroded or dirty.
Typically, the longer the leads and the more connection points, the more resistance in the weld cable. The resulting voltage drop can lead to arc performance issues unless operators compensate for the drop — leading to potential weld quality complications.
In conventional equipment, operators must manually adjust for this by setting the voltage higher than necessary at the power source to ensure they get the voltage they want at the feeder. This is often a guessing game, requiring welders to set a certain voltage, weld for a bit, then either radio another worker or return to the power source to adjust voltage again before walking back to weld more. Welders may adjust this several times before the right level is dialed in.
This is inefficient and may prompt the quality control inspector to question why the power source voltage exceeds what is permitted by the welding procedure. Voltage drop can be mitigated with Miller® technology to eliminate the challenges posed by cable length. To achieve a consistent voltage arc, consider the following:
- Automatically adjust voltage: Cable Length Compensation (CLC™) technology, available on XMT® 350 FieldPro™ welding systems and XMT 400 ArcReach and XMT 650 ArcReach systems, ensures that the voltage welding operators set is the voltage they get — even hundreds of feet from the power source. The power source measures the resistance in the weld circuit, calculates the voltage drop in the weld leads and makes the necessary adjustments. This process happens automatically once the operator sets the voltage and before the initial arc strike.
- Choose proper size cables: To help optimize arc performance and quality on the jobsite, it’s also important to use the proper size cables, make sure all connections are tight and free of corrosion, and keep weld cables straight and uncoiled during welding.
Tip No. 3: Troubleshoot wire feeding issues
Wire feeding issues can lead to poor weld quality, increased downtime and equipment damage. While these can stem from numerous factors, most can usually be addressed with one of the following fixes.
- Choose the right drive roll: When selecting the drive roll size and type, consider the size and type of wire. Tubular wire is softer and requires a knurled drive roll, which has teeth to grab the wire and help push it through. However, knurled drive rolls shouldn't be used with solid wire because the teeth will cause shavings to break off, which can clog the liner. Use a smooth, V-groove drive roll with solid wire. Taking the time to swap out the drive roll to match the wire helps promote consistent wire feeding and reduces maintenance on the MIG gun.
- Set proper drive roll tension: Setting the tension too tight can deform the wire, but too little tension can cause wire slippage. To set proper tension, release the tension on the drive rolls, then increase tension while feeding the wire into a block of wood. Continue increasing tension one half-turn past wire slippage.
- Trim the liners: Arc instability, bird-nesting and burnback can result from liners that are kinked, worn, the wrong size or partially plugged. Blow compressed air through the liners to remove dirt and debris and to improve feeding performance. Promptly replace the liner if a blockage is found, and always trim the liner per the manufacturer's recommendation.
- Redesigned inlet guide: Feeder technology has improved over the years, resulting in smoother and more consistent wire feeding. Miller wire feeders use an inlet guide designed to reduce wire drag coming off the spool for more consistent wire feeding into the drive rolls, leading to better wire feeder performance.
Tip No. 4: Ensure a steady arc
Portable generators can be a source of inconsistent primary power on the jobsite since they may not provide a smooth electrical wave. Generator technology has improved over the years, making inconsistent power a less common problem. Since many jobsites still use older, legacy generators, it’s important to look for welding solutions designed to protect against inconsistent power and ensure a steady arc.
- Automatically adjust for inconsistencies: One option is Miller® Auto-Line™ power management technology, which allows the machine to automatically adjust for inconsistencies in the primary power being applied to the machine without impacting the output. Even if incoming voltage varies widely, the circuit ensures a steady welding or cutting arc. Auto-Line also carries with it the additional benefit of being able to plug into any available single- or three-phase power 220-575V as equipment is moved from job to job.
- Use updated equipment: Transformer-based equipment often requires greater power consumption on a jobsite. Newer welding power source technologies can provide much greater power efficiency and save in operational costs.
Tip No. 5: Keep a focus on safety
Several of these welding technologies, including the capability for complete control of parameters at the weld joint provided by ArcReach technology and Wireless Interface Control, help improve jobsite safety.
Out of 5,486 worker fatalities in private industry in 2022, about 20% were in construction, according to the Bureau of Labor Statistics (BLS). Falls were the leading cause of deaths in construction in 2022. Technology that reduces the number of trips welders must make on a crowded jobsite to change parameters ultimately reduces slip, trip and fall hazards.
Improving safety can also have a financial impact by reducing the cost of worker downtime, insurance or workers’ compensation payments. Jobsite safety records may also be reported in some contract bidding, which means contractors with poor records can have a harder time winning bids.
Using the right personal protective equipment (PPE) is another simple way to increase safety in an operation. Wearing the correct helmets, clothing and respirators can protect welders from hazards such as heat, sparks, fumes and radiation.
Tip No. 6: Track welding productivity and cost savings
Tracking things like arc-on time, amperage, voltage, wire feed speed and deposition rates can help identify inefficiencies, optimize welding procedures and provide data-driven insights for continuous improvement. Tracking welding productivity is important because it can help reduce costs, improve quality and increase profitability. Technology can also make an impact:
- Productivity gains and cost savings: Using equipment with ArcReach® technology can mean saving up to 250 hours per operator per year. Plus, when the control cable is gone, cable inventory is reduced — as are the maintenance expenses for repair or replacement.
- Advantages of high-quality consumables: The quality of the consumables used in welding can also affect productivity, performance and quality. Consumables that are poorly designed or manufactured can cause excessive spatter, porosity, burnback, wire feeding issues and other problems that require rework or downtime. Using high-quality consumables may cost more upfront, but they can save money in the long run by reducing the frequency of tip changes, liner replacements and troubleshooting. AccuLock™ consumables offer a simple and reliable design that helps prevent inaccurate liner trimming, reduces burnbacks and bird-nesting and extends contact tip and liner life. By using high-quality consumables, welders can improve their welding outcomes and efficiency.
Improving jobsite productivity
On jobsites, it’s all about staying ahead of schedule and delivering quality projects within budget, while keeping employee safety a priority.
As a skilled labor shortage impacts the industry and competition for contracts intensifies, contractors can implement welding best practices — along with more productive welding processes and new technologies — to help improve productivity, safety and quality.