One of the joys of working on the internet is that corrections can be made quickly.  You know what I’m talkin’ about:  typos, wrong part numbers, confusing images….

Print, however, is different.  An operations manual, for example, printed hundreds of thousands of times over– with an error–  could potentially cause confusion, and none of us are immune– not even the most respected manufacturers.

We recently ran across just such a case, when a manufacturing engineer contacted us via this very blog, in response to an article we’d posted about the installation of the ceramic electrode insulator/gas distributor on the Thermal Dynamics 3A Plasma Arc Welding Torch.

Allen wrote:

The article about Plasma Arc Welding Tips from June 2007 shows a particular way to install the insulator sleeves part # 9-2240 for a Thermal PAW 3A torch. This is opposite to what my Thermal factory manual says. The manual says the collar goes towards the tip and your article says the collar goes to the torch cap. I’m confused now.

I emailed a response that included a direct link to the manufacturer’s data sheet on the 3A PAW torch which correctly shows the direction of the installation of the part.

Imagine my surprise when Allen wrote back to tell me he had called the manufacturer himself and a service tech confirmed that the manual was incorrect!

Now I’m not saying we’re always right, but I am saying it is always a good idea to double check, and ask questions.  When you’re talking about Plasma Arc Welding, there are so many variables, and the last thing you want is for you an incorrectly installed part to cause a $500 torch failure.

At Arc-Zone.com we carry a complete line of performance proven no-OEM plasma arc welding torches and replacement parts for the Thermal Dynamics(R) torches, manufactured to exacting specifications to meet your production needs.

So give us call if you’re in need of plasma arc welding torch replacement parts, accessory kits, and be sure to ask about our blanket purchase order program.  We’ll make sure you not only have your parts installed correctly, we’ll make sure you have the parts you need when you need them.

As many TIG welders know, thoriated (red) tungsten has in the past, been a preferred tungsten electrode blend.  But that’s old skool thinking– there’s better options out there… more on that later.

If you’re like me, you enjoy learning about all kinds of things especially as it relates to welding and metal fabrication.  I recently stumbled across this column over at Salon.com, Blogging the Periodic Table.  It’s a fascinating look at each of the elements in the periodic table–  and each one has a story.  You can read all about Thorium. Though this column doesn’t include information on welding, there some interesting and fun facts sprinkled throughout.

Now if you’ve been TIG welding for a while, you’re all too familiar with the RED tungsten electrodes.  This thoriated blend of tungsten electrode is popular because it is a good general purpose electrode (good for all metals and all machines) has excellent arc behavior and lasts long….  because of the nature of thorium, however, there are some health concerns due to vapors and grinding dust. At Arc-Zone we recommend you only use it if you are contractually required to, especially as there are better alternatives out there.

For more detailed information on health and safety concerns regarding the use of thoriated tungsten electrodes, check out the AWS Safety and Health Fact Sheet: Thoriated Tungsten Electrodes.

We almost always recommend our ArcTime Hybrid Tungsten… it is truly a state-of-the-art improvement over the old thoriated electrodes with excellent ignition properties, low burn off rate and it lasts a long time! I’ll let our spokes model tell you more about it:

To explore other options, check out Arc-Zone.com’s Guide to Selecting Tungsten Electrodes.

I don’t think I’ve ever laughed so hard at work before!  This guy has a gift – if not for welding, then definitely for writing!

Attempting to weld in the age of duct tape

Al Batt, Tales from Exit 22
Published Wednesday, March 10, 2010

I don’t like to wear socks.

I wear them but I don’t like it.

I consider socks to be a fire hazard.

I took a welding class at a college that once thrived in Waseca.

It wasn’t my idea. It was my employer’s idea. He felt that the duct tape I used wasn’t as strong as a weld. He was annoyingly conscientious. Welding started during the Bronze Age, and it survives into the Duct Tape Age. I went to college during the day and worked nights. The welding class gave me something to fill those hours that I had been wasting on sleep.

My father had taught me how to weld with a derelict welder he had rescued from a junkyard. It was a serious stapler that performed basic farm welding with little attention paid to aesthetics.

On the farm, I welded broken wagon tongues and tractor hitches. I gave up welding once I quit breaking wagon tongues and tractor hitches.

I would have been happy not knowing anything more about welding. Welding isn’t even an Olympic event. It could be in the Winter Olympics. Replacing the brooms with welders would make curling a little more exciting.

CONTINUE READING ONLINE ->

Excited for the new Iron Man 2 movie coming out this summer?  Well, while you’re waiting, why don’t you check out this new IronMan 230 All-in-One MIG Welder from Hobart Welders?  It has everything you could want in a MIG machine — we only wish it had a bit more in common with its namesake (flying while welding anyone??)

Hobart Introduces IronMan 230 All-in-One MIG Welder with Superior Arc Quality and Greater Precision
Jon Crowley | Jan 14, 2010

Hobart Ironman 230

The IronMan™ 230 is a total redesign of the full-size MIG platform, outperforming the competition on arc quality, voltage control, duty cycle and value. It delivers 30-250 amps of pure power in a heavy duty cabinet. The arc of the new IronMan™ 230 is optimized to deliver a flawless weld, making spatter and post-weld cleanup almost non-existent. The IronMan™ 230 easily runs aluminum – just add the optional Hobart DP-3545-20 spool gun and you’re ready to weld aluminum from 18 gauge to 1/2″.

For improved feedability with aluminum wires or for extended reach with other wires add the Hobart 3545-20 spool gun with its 20 ft. cable length.

CONTINUE READING ONLINE ->

What are you doing this Sunday?  Planning on going to church?

How about Metal Church, with your favorite preacher, Jesse James?!?

An introduction to friction stir welding

By Jeff Defalco, Contributing Writer

September 15, 2009

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.

Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects. Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.

History

Friction stir welding was invented by The Welding Institute (TWI) in December 1991. TWI filed successfully for patents in Europe, the U.S., Japan, and Australia. TWI then established TWI Group-Sponsored Project 5651,”Development of the New Friction Stir Technique for Welding Aluminum,” in 1992 to further study this technique.

The development project was conducted in three phases. Phase I proved FSW to be a realistic and practical welding technique, while at the same time addressing the welding of 6000 series aluminum alloys. Phase II successfully examined the welding of aerospace and ship aluminum alloys, 2000 and 5000 series, respectively. Process parameter tolerances, metallurgical characteristics, and mechanical properties for these materials were established. Phase III developed pertinent data for further industrialization of FSW.

Since its invention, the process has received world-wide attention, and today FSW is used in research and production in many sectors, including aerospace, automotive, railway, shipbuilding, electronic housings, coolers, heat exchangers, and nuclear waste containers.

“If you can’t stand the heat, get out of the kitchen.”

This expression makes absolutely no sense if you’re in the profession of welding.

#1:  If you can’t stand the heat, why the heck are you a welder?

#2:  There is no kitchen.  What kitchen?  If you’re welding in a kitchen, get out of that kitchen. Right now! There are gas mains!

#3:  If you can stand the heat, and you’re not in a kitchen, then why would you move?  Stand right there!

In fact, let’s add some more heat.  Let’s add some… friction.

That’s right, you heard me. Friction, as in friction stir welding. FSW. It’s all the rage in… in…

Just read.

An introduction to friction stir welding

By Jeff Defalco, Contributing Writer
September 15, 2009

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.

Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects.

Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.

CONTINUE READING ONLINE ->

Interested in learning about restoring classic cars? Well, you’ve come to the right place!

The folks over at Second Chance Garage have given us a step-by-step guide to choosing the right welder for the job:

Selecting the Right Welder for Classic Car Restoration Projects

What Welder To Use?

The most common welders used in auto restoration, therefore, are MIG (metal arc welders, gas or flux-cored), TIG (tungsten arc welders using shielding gas) and Arc Welders (the traditional “stick” electrode).

To choose the most appropriate one for your needs, you have to consider the following parameters:

* What is the maximum and minimum thickness of metal to be welded? Fortunately, automobiles use metals that fall into a relatively narrow range.

* What is the metal type? Again, automobiles generally are made of steel and, rarely, aluminum.

* What is the normal position the welding “head” will be put in? Do you need to do a lot of welding overhead? The answer is usually no here.

* How much current is available in your shop and do you have 220 volts? Check your circuits.

Let’s be frank. Our overwhelming favorite type of welder is the MIG. We’ll explain why shortly, but first we’ll give an overview of the other contenders. Here we go!

CONTINUE READING ONLINE ->

Once you’ve chosen a welder, come on over to Arc-Zone.com where you’ll find MIG guns, TIG Torches, Oxy-Fuel Torches, Plasma Arc Cutting Torches…  not to mention some really trick accessories like Trailing Shields, and everything you need to Weld Like a Pro!

“Is it the machinery or the operator?” That was always my mother’s question when a piece of equipment wouldn’t cooperate with my demands.  Was it the computer’s fault that the printer kept jamming?  Or perhaps… was it the fault of the operator?

The same applies to the world of welding.  Is it really the metal’s fault when a weld doesn’t hold true?  Can you blame the steel for warping?  Was it the machinery‘s fault, or was it the operator?

‘Bad’ steel — the ultimate scapegoat

By Art Hedrick

August 1, 2009

It seems like every time there is a problem making a good part, the steel is blamed. Often the root problem is the process used to cut and form the steel — the combination of the die, the press, and the lubricant.

What the heck is “bad” steel? It seems like every time there is a problem making a good part, the steel is blamed. Cracking problems? It’s bad steel. Wrinkling problems? It’s bad steel. Springback problems? It’s bad steel. Cold and rainy outside? It’s bad steel. You get the idea.

As a tool- and diemaker, I, too, used to blame the steel for many problems. However, as I learned more about the processes of stamping and metal forming, I quickly came to the conclusion that the steel is not always to blame.

When I’m asked to consult for steel suppliers, the usual scenario is that they are being accused of selling bad steel to their customer, and they want me to go into the stamping facility and defend their honor. To be perfectly honest with you, most of the time nothing is wrong with the steel. Often the root problem is the process used to cut and form the steel — the combination of the die, the press, and the lubricant.

I’m not suggesting that there is never a problem with the steel. Stampers have most certainly received steel that was out of spec. What I am suggesting is that you take a hard look at the data before you make a rash decision.

‘Bad’ steel — the ultimate scapegoat

By Art Hedrick
August 1, 2009

It seems like every time there is a problem making a good part, the steel is blamed. Often the root problem is the process used to cut and form the steel — the combination of the die, the press, and the lubricant.

What the heck is “bad” steel? It seems like every time there is a problem making a good part, the steel is blamed. Cracking problems? It’s bad steel. Wrinkling problems? It’s bad steel. Springback problems? It’s bad steel. Cold and rainy outside? It’s bad steel. You get the idea.

As a tool- and diemaker, I, too, used to blame the steel for many problems. However, as I learned more about the processes of stamping and metal forming, I quickly came to the conclusion that the steel is not always to blame.

When I’m asked to consult for steel suppliers, the usual scenario is that they are being accused of selling bad steel to their customer, and they want me to go into the stamping facility and defend their honor. To be perfectly honest with you, most of the time nothing is wrong with the steel. Often the root problem is the process used to cut and form the steel — the combination of the die, the press, and the lubricant.

CONTINUE READING ONLINE ->

There is a new welding process, recently developed in Europe, that is said to not only improve welds but also lower the skill required to make them.  It uses a “manual and automated GTAW wire feed control combined with a hot-wire power source” that improves the wire feed, weld pool, and weld deposition and decreases gas consumption.

Enhancing the GTAW process

By Ed Craig, Contributing Writer
September 15, 2009

Gas tungsten arc welding (GTAW or TIG), a popular process for high-quality manual welding, has its limitations and requires highly skilled operators. A process used in Europe addresses those limitations, enhances productivity and weld quality, and reduces the skill level required to GTAW.

For at least six decades, traditional gas tungsten arc welding (GTAW or TIG) has been considered the process of choice for attaining high-quality welds in any metal application. However, this process has certain drawbacks, such as the weld energy limitation influenced by the weld pool dynamics and typically slow manual wire feed rates. Manual GTAW requires highly skilled operators who possess the dexterity necessary to feed the wire. Manual GTAW techniques vary, and the weld-wire-to-arc and weld puddle placement are inconsistent.

CONTINUE READING ONLINE ->

This has to be my favorite topic post ever from the Miller Discussion Boards. It started three years ago, and amazingly, continues up until, probably whenever you’re reading this! From the over five hundred responses I picked out twenty of my favorites – see if you recognize any!

You Might Be a Welder If…

Got any more YMBAWI quotes?  Let’s start another marathon thread here!