Cover Story

WD Mar 24 - Saving Money with Filler Metals
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In some applications, replacing a 0.052-in. flux cored electrode with a 1/16-in. electrode can help ensure good sidewall fusion and increase the deposition rate. 

Saving Money with Filler Metals

One of the easiest ways to improve productivity with filler metals is to use less of them, and to achieve that goal, all companies need to do is to follow the welding procedure specification (WPS) for weld size.

News and Updates

Tech and Industries

Four New Cobots Are Showcasing a New Era of Automation

Created by Universal Robots (universal-robots.com), the UR30 is a compact, 30-kg (66-lb) payload collaborative robot (cobot). The cobot enables extraordinary lift. Its motion control ensures the perfect placement of large payloads.

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AWS News

Why Fabricators Continue to Choose Automated Arc Welding

Over the last three years, I’ve visited more than 40 different facilities, and one common denominator I’ve noticed is companies are moving toward welding automation or, at the very least, are considering investing in automated welding.

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Tech and Industries

Weld Setting Optimization for Collaborative Robots

Weld Setting Optimization for Collaborative Robots There are many videos showcasing how collaborative robots, or cobots as they’re commonly known, can weld. What is not always shown and less understood is how to maximize welding efficiency with cobots.

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Tech and Industries

Remote Manufacturing: Redefining the Skilled Workforce

Remote work is transforming the manufacturing industry and its skilled human workforce.

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AWS News

The Welding Advocate

Tiffany Orff is a multi-business owner and prison vocation teacher who shares the word about welding.

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AWS News

Forging Your Financial Future

For many welders who have embarked on a career that promises a bright future filled with opportunities and financial stability, making the right decisions when it comes to spending and saving money is important. 

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AWS News

Strengthening the Volunteer Experience and Board Governance 

AWS president Michael Krupnicki speaks on the invaluable culture of the AWS community. 

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Careers and Education

What Drives the AWS Automotive Committees?

This Standards Action story brings attention to the AWS D8 Committee on Automotive Welding and its subcommittees. Keep on reading to find out more about their importance in the automotive industry and volunteering opportunities. 

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Processes

What to Know about Aluminum GMAW Setup

Aluminum gas metal arc welding (GMAW) requires attention to detail and a base of knowledge to be successful. It’s also necessary to take precautions to avoid common mistakes. 

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AWS News

Strengthening the Volunteer Experience and Board Governance 

AWS president Michael Krupnicki speaks on the invaluable culture of the AWS community. 

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AWS News

AWS Student Member Goes from the Family Farm to the Welding Classroom

Growing up in a small rural community in Economy, Ind., Jaron Baker was raised on his family farm that has been passed down from generation to generation for more than 150 years.

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AWS News

What’s on the Horizon for AWS Standards

New technology and improved processes are enhancing these publications.

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AWS News

Automated Solutions for Bucket Welding Help Keep Manufacturers and the Earth Moving

Playing in the dirt has never been so high tech! A far cry from the metal Tonka trucks of our youth, today’s excavating equipment is massive and specialized from the electronics that power them to the buckets that scoop tons of earth in each fell swoop.

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AWS News

Laser-Based Literature and Technologies Take Center Stage

Laser technology continues to adapt to the industry’s manufacturing needs. The literature is also refined for students and users, presenting new laser-based developments.

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Tech and Industries

How ClearLight 2.0 Helmet Lens Technology Benefits Welders with Better Visibility

This welding helmet lens technology delivers more color and clarity before, during and after every weld

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Processes

Recognizing and Handling an Oxyfuel Torch Backfire

Learn the crucial steps to spot and safely shut down an oxyfuel torch backfire, ensuring a secure work environment.

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Processes

Optimizing Productivity with Grinding Wheels

Metal grinding is a demanding job. But it can be made easier by choosing the right product and the right tool for the specific application and using them properly.

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Tech and Industries

Examining the Flexibility of Additive Manufacturing

Changes driven by rapid innovation in 3D printing (3DP) technologies are afoot. Direct metal laser sintering (DMLS) has allowed an impressive list of metals to be built with additive manufacturing.

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Tech and Industries

Choosing PPE for Welding

Selecting the right safety equipment and garments is essential. This article discusses the critical factors when choosing personal protective equipment (PPE).

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Tech and Industries

Welding on the Farm

Welding on the farm has a long tradition, and sometimes it’s all that keeps things moving. But farm welding brings its own challenges. Sometimes repairs need to be made where power isn’t availa-ble. Farming equipment and machines aren’t all made from the same metal. And let’s face it, farms come with dirt and, well, more than dirt. Neither mix well with welding.

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Processes

Staying Safe When Using Abrasive Products

In a manufacturing environment, safety isn’t covered by a one-time seminar or meeting. Here are some tips for safe use of abrasive products and why safety is critical for the operator’s well-being and productivity.

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Processes

Enhance Welding Efficiency on Construction Jobsites

For construction contractors and steel erectors searching for ways to offset project slowdowns and labor challenges, paying attention to the following four tips on welding operations can help improve efficiency and performance on the jobsite.

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Tech and Industries

Cobots Take Grinding from Good to Great

Cobots Take Grinding from Good to Great Professional welders know a good weld when they see one. They also know that there are some obvious reasons as to why good weld beads are ground once finished, such as better appearance, proper joint fit, or paint prep just to name a few. But great grinding takes time, precision, and a lot of hard work.

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Processes

A Comparison of Oxygen- vs. Air-Acetylene Torches

When it comes to brazing, there are two main equipment options to consider: oxygen-acetylene or air-acetylene torches. Traditionally, oxygen-acetylene setups have been dominant in many air-conditioning brazing applications across the United States. However, air-acetylene torches present a viable alternative. Contractors who have experimented with air-acetylene torches often appreciate their portability and lower operating costs, which can outweigh the slight trade-off of longer heating times.

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Tech and Industries

How Poor Air Quality from Welding Fumes Harms Workers and Shop Productivity

Fumes generated during welding processes destroy air quality if not properly controlled. Dust collection systems need to be designed for the specific types of metals being welded and the regulations for permissible exposure limits and minimize hazards.

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Careers and Education

AWS Sustaining Company Membership Solidifies Colorado Business’s Commitment to the Industry

AWS’s Sustaining Company membership is intended for forward-thinking organizations that want to promote an internal culture of continuous improvement and take an active role in shaping the industry. 

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Processes

Using Lean Principles to Improve Safety and Productivity in the Welding Shop

Adam Lawrence of Process Improvement Partners LLC, Lancaster, Pa., relates how by using lean business principles, he helped a welding shop cut its response time to major equipment issues from over two hours to under three minutes.

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Tech and Industries

The Building Blocks to an Automated Robotic Welding System for Longer, Leaner Operations

The Building Blocks to an Automated Robotic Welding System for Longer, Leaner Operations Here’s how an automated welding system provider works with its customers to build these systems from the group up, thus mitigating risks and smoothening the transition to fully automated.

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Tech and Industries

Key Considerations for a Welding Fumes Extraction System

Every industrial manufacturing facility has unique processes. There’s no one-size-fits-all solution for managing welding fumes. This Q&A can help facility managers consider the most effective fume extraction strategy.

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Tech and Industries

Solving The Welder Shortage With Cobots

The skilled welder shortage is a global problem, but two companies overcame skepticism and embraced automation and robotics to bridge the gap between the number of welders needed and the number of available qualified welders.

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Tech and Industries

Proper Robotic Welding Gun Configuration

The welding gun is a vital piece of equipment in a robotic welding system, serving as the conduit for the welding wire, gas, and power.

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Tech and Industries

Fabricating the Enterprise’s Newest Successor

On August 27, 2022, Olympic gold medalist Katie Ledecky gave the command to Big Blue crane operator Charlie Holloway to lower the Enterprise (CVN 80) ceremonial keel unit into dry dock number 12 at Newport News Shipbuilding (NNS), Newport News, Va., a division of HII.

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Processes

Top Four Reasons to Use Arc Thermal Spray for Machine Components in Your Job Shop

Arc thermal spray, also known as twin wire arc spray, is one of the older and simpler forms of thermal spray coating. Thermal spray technology has come a long way, from spraying basic metals and simple alloys to, now, spraying extremely hard ceramics and carbides.

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Processes

Additive Manufacturing in a Naval Aircraft Carrier Construction Project

Additive manufacturing technology, or 3D metal printing using layers of welds, enabled Newport News Shipbuilding to stay on schedule with construction of the nuclear-powered aircraft carrier Enterprise (CVN 80) for the U.S. Navy.

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Careers and Education

Improving Communication between Generations

Each generation is different in important ways, but we can work to close the widening generational gap in the welding industry and revitalize the working relationships that are in critical need of repair. 

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Tech and Industries

Additive Manufacturing in a Naval Aircraft Carrier Construction Project

Additive manufacturing technology, or 3D metal printing using layers of welds, enabled Newport News Shipbuilding to stay on schedule with construction of the nuclear-powered aircraft carrier Enterprise (CVN 80) for the U.S. Navy. 

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AWS News

A Driving Force for Weld Quality

The AWS D8 Committee on Automotive Welding is responsible for the development of AWS standards on all aspects of welding in the automotive industry.

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Tech and Industries

How Specifications Keep Aerospace Vehicles up to Standard

Regardless of how they're used, all aerospace vehicles are manufactured and repaired according to specifications. Manufacturers and tiered suppliers have stringent requirements that govern their processes to ensure components meet the end requirements.

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Careers and Education

Fixing the Labor Gap: Connection is Key

Leaders will need to rise above, offering mentorship that includes valuable interpersonal skills training, the ability to handle conflict, teamwork, listening, and more.

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Processes

How to Make a Quality Shielded Metal Arc Weld

Welding student Mason Blaine performs a fillet weld on a T-joint while welding instructor Brian Wall watches his in-process bead placement. Pictures by Jodi Glass.

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Tech and Industries

Enhance Welding Efficiency on Construction Jobsites

For construction contractors and steel erectors searching for ways to offset project slowdowns and labor challenges, paying attention to the following four tips on welding operations can help improve efficiency and performance on the jobsite.

see more
Careers and Education

The Education of a Welding Teacher: Tips from the Field

Throughout my nine years in the welding industry, I’ve had the opportunity to explore the world of teaching. I’ve learned a lot, and I’d like to share my experiences with you.

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Careers and Education

Beyond the Arc: Welding Engineering Explained

“I have never heard of a welding engineer. What is a welding engineer?” That is a common response I have heard throughout my career.

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AWS News

D20 Additive Manufacturing Technical Committee Makes a Call to Action

The AWS D20 Committee on Additive Manufacturing met at AWS Headquarters to discuss a new American national standard. D20 Chair Bill Mohr (middle, in a white shirt) leads the discussion.

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Processes

Building the New with Additive Manufacturing

Additive manufacturing (AM) of metals is a growing field that builds on the knowledge of metal and alloy welding behaviors. AM creates new material by fusing metal feedstock layer by layer using a computer-controlled heating plan.

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Inspection

CWIs/SCWIs Can Get Certification Endorsement to Perform Welding Procedure Qualifications

The American Welding Society (AWS) proudly introduces the Welding Procedure Qualifier Endorsement, developed for existing Certified Welding Inspectors.

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Tech and Industries

Real-Time Data Tracking During Welding Operations

What if someone told you it is possible to capture welding data for each weld joint on a particular structure? You can see everything from amperage and voltage information to data that show specifications have been met. 

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Careers and Education

AWS Education: Welding Education for the Entire Career Arc

Welding is a dynamic industry with endless learning opportunities. And no matter where you are in your career, AWS Education offers comprehensive training resources that light the way toward your next goal.

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Inspection

Welder Performance Qualification and Welder Certification

Misconceptions about welder certification terms and definitions are discussed.

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Processes

Controlling a 7-Axis Robot for Continuous Internal Bore Welding

Gas tungsten arc welding (GTAW) is not commonly used in robotics because the process is erroneously believed to be too slow or complicated for robotics. But technological advances are changing that.

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AWS News

How Technical Committee Volunteers Help Develop AWS Codes and Standards

Standards are paramount to the infrastructure that makes up our modern civilization. And at the heart of these standards are technical committees, steering the propulsion for innovation through all the processes of the welding industry.

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AWS News

How to become a Standards Committee Member

AWS Standards Committees consist of over 1,800 volunteers, 200 committees, tasks groups, and 13 AWS staff. Together, they develop standards and other technical publications to serve the ever-changing welding industry

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AWS News

AWS Standards: What They Are and how They're Developed

AWS is the leader in developing codes and standards that ensure consistency and quality across products, processes, and industries. But, what are Standards and Codes, and how are they developed?

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Inspection

The Benefits of Eddy Current Array Examination of Stress-Corrosion Cracking

Stress-corrosion cracking occurs when cracks link corrosion pits, causing multiple cracks in all orientations in the base material of pressure vessels, pipes, and storage tanks.

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Processes

Staying Safe during Resistance Welding

Resistance welding (RW) is a thermo-electric welding process in which the weld is made by a combination of pressure and current.

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Inspection

Complementary Inspection Certifications

A discussion about additional certifications that enhance the CWI credential to broaden the inspection career.

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Careers and Education

Harnessing the Teaching Power of Augmented Reality

Lewis and Clark Community Coll­ege (L&C) in Godfrey, Ill., is using augmented technology to maximize learning, facilitate instruction, and reduce costs.

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Careers and Education

Leveling Up Skilled Trades Education

While we often see virtual reality (VR) and augmented reality (AR) used for gaming, entertainment, and other commercial ventures, these technologies also have great potential for welder training.

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Processes

Material Conditions and Filler Metal Selection

When proper cleaning and part preparation of dirty or coated materials prior to welding isn’t possible, choosing the right filler metal for the base material conditions can help address quality issues and improve results.

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Tech and Industries

Multiaxis Laser Cutting in the Automotive Industry

Laser technology and the automotive industry have gone hand in hand for a very long time.

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Processes

Creating a Safe Environment While Gas Metal Arc Welding

You can make sure you are following the best preventative measures when working with the GMAW process by following the procedures outlined in this article.  

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Processes

An Introduction to SMAW and SAW Consumables

Quality shielded metal arc welding (SMAW) and submerged arc welding (SAW) welds typically start with using a quality consumable. For both of these commonly-used processes, choosing the right consumable for the application is key.

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Tech and Industries

The Importance of Understanding AISC and AWS Codes

Following the requirements of codes and standards can save you significant dollars, create margin, and provide your firm with a quality reputation.

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Tech and Industries

Choosing the Right Welding Screen or Curtain

Many factors must be considered when choosing a semitransparent welding screen or curtain for protecting workers near the welding operation from harmful UV and blue light radiation.

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Careers and Education

How to Pass a Weld Test

In my journey as an instructor and inspector, I’ve monitored countless weld tests. More importantly, I’ve also taken many welding tests (known as welder performance qualification tests) during my career as a welder. These tests ranged from horizontal fillet welds to 6G ASME pipe tests. When the inspector certified my weld tests, I was qualified for production.

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Processes

Gaining an Edge on New Cutting Tools

From cutting machines and tables to saws and flap wheels, the following highlights some of the newest tools in the metal cutting industry.

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