The Need and Significance of Metal Fabrication Welding

The Need and Significance of Metal Fabrication Welding

The process of metal fabrication welding is as much an art as it is a science. This process entails joining two metal pieces into a single piece with the use of heat. In most cases, the two pieces of metal to be joined together are molten at the targeted joint and they are further bonded by using a filler material that securely holds these two materials together. While the use of heat (usually in the form of a flame) has been the conventional welding method, today you shall find lasers, electric arcs and even ultrasound to carry out this process.

This method is also used for prototype machining, in which an archetype of a machine is made and tested for feasibility before the final product can be made. Since both these techniques require a considerable amount of skill, one needs to partner with a reputable firm for such services.

A firm that boasts of metal fabrication welding as their core competency is more likely to offer you a better service. Since these services are used for the high end manufacturing of large and small industrial machinery or components, one cannot take a chance with quality. So whether you need a unique product or a batch of components, you can outsource these requirements to a machining firm. This process begins with a design-so a lot depends on the accuracy of the design that is being created for you.

These services are required by several industries including but not limited to aerospace, tooling and fixtures, assemblies, composites, energy sector, wind, hydro power, nuclear power, pipelines, marine industry, infrastructure construction and many others.

Now let’s discuss some of the salient features of Metal Fabrication Welding:

  • This technique of joining two metals endows the final part with strength and stability.
  • Parts or components such as valves can be made according to tight tolerances and in adherence to industry codes.
  • It is possible to create machines and components that can offer you different work patterns and outputs.
  • Welding can be performed on different shapes and sizes of welds. It can help join metal pieces at different angles.
  • Once the welding process is executed, its strength can be ascertained with the help of several tests. This helps to check defects such as cracks, incomplete fusion, distortion, undercutting etc at an early stage. The errors can then be rectified suitably. Testing errors is an important aspect of Prototype machining.

When the process of welding is carried out, the risk of distortion exists. Only an expert machinist can help control such risks. In addition, if you need to procure highly complex or intricate parts with difficult metals and geometrical shapes, it is advisable to enlist the services of a reputable metal fabrication welding firm.

I am a registered Professional Engineer & Certified Metal Fabrication Welding Inspector who has worked the last ten years. My interest is the training aspect on Prototype machining, metal fabrication welding processes, machine tools, conducts through seminars.

Article Source: http://EzineArticles.com/7167087

Sheet Metal Fabricators – Hot Tips For Welding Flat Rolled Steel

Sheet Metal Fabricators – Hot Tips For Welding Flat Rolled Steel

As fabricators acquire experience welding SCS strip steel we discover great news with regards to better weld quality, cost savings on filler wire and, of course, decreases in toxic welding fumes as opposed to welding P&O steel. Still, we sometimes learn of a new user having problems with too much weld spatter while welding the SCS steel. Research show that modest alterations in shielding gas and filler wire feed eradicate excessive spatter and produce larger cost savings on consumables. This write-up offers the foundation of theSCS sheet steel strengths and describes welding practices that permit sheet metal fabricators to enjoy those rewards while steering clear of the excessive spatter.

Consistently Stronger Welds.
Six years ago comparable samples of welded SCS treated steel and Hot rolled pickled and oiled sheets were tested metals testing laboratory. It required an average 580 pounds greater shear load to induce failure in welded SCS treated steel samples than the P&O samples.

SCS treated steel benefit comes from greater weld integrity. A certain amount of weld arc’s energy would go to burning up the oil on Hot band oiled sheets. This brings out even even more contaminants to a Pickled and oiled surface that is already fairly dirty when compared to SCS sheet steel. The net outcome is to lower the integrity of HRPO welds compared to SCS treated steel welds.

That Issue of Excess Spatter.
Most sheet metal fabricators who switched to SCS treated steel reported cleaner, stronger welds with really no spatter. However, a handful noted unacceptable amounts of spatter.

To discover the underlying cause, The Material Works, Ltd. recruited the support of the Illinois Manufacturing Extension Center (IMEC) which provides technical services to companies. IMEC’s project manager partnered with Optimum Engineering Solutions, Inc. to perform controlled welding tests of SCS sheet steel. They duplicated the welding procedures of fabricators who reported excessive spatter and observed similarly undesirable results.

Then they, evaluated adjustments in shielding gas make up and filler wire feed rate. Changing from 90%Argon-10%CO2 to 95%Argon-5%Oxygen enhanced arc stability and greatly decreased spatter. Decreasing wire feed speed worked well with the new gas recipe. Using ER70S-6 filler wire at a slower feed rate with the Argon-Oxygen selection delivered notably better penetration and improved bead appearance when welding at the same speed.

The study discovered that the best parameters for welding SCS sheet steel (or Oiled strip steel for that matter) were different from what these fabricators had been using. A change to the optimized shielding gas and filler wire combination not simply assures exceptional SCS treated steel welding performance, it also provides savings on consumables!

The gas supplier for the analysis sells the Argon-Oxygen mix at five percent under the Argon-CO2 mix. But even bigger savings are realized on filler wire. The more even weld bead you receive with optimized SCS sheet steel parameters translates to less filler material for a given weld joint. Couple that with a lower wire feed rate for the identical welding rate, and the savings in welding wire can reach 30%.

Article Source: http://EzineArticles.com/4042684

Different Types of Stainless Steel Has Different Welding Properties

Different Types of Stainless Steel Has Different Welding Properties

If you are thinking about the steel fabrications, it is wise to perhaps think about the welding requirements later. After all, the steel fabrications are done by using different types of steel alloys. Now, they have different properties, and features. Therefore, it is important that you choose the right alloy for the purpose. Remember, some of the alloys provide high corrosive resistance. But, they may not be high in terms of the machinability. So, it is really essential that you choose the right material that will complement the purpose and the environment of the fabrication. Another very important factor to consider is of course the welding properties. Actually, there are some steel alloys that can’t be used for welding.

A great exception to this is of course the austenitic stainless steel. This is the type is readily welded. The great thing with this type is that every type of electric welding methods can be utilized for this purpose. The standard equipments are useful for the welding process. However, you must note that these facilities are not applicable to the free machine grade versions of this type of stainless steel. If you are thinking about heavy sections that need welding, you should be going for the stabilized grades or grades that contain low carbon. However, you can also use the improved machinability grades for this purpose.

Another type of steel that you can use for welding is the duplex steel. Though they are not as good as the austenitic types, still you can use all the standard methods and consumables though the 2209 is the most used. However, the good thing with this type of steel is that it is less coefficient in thermal expansion than the austenitic steel and in fact, matches the carbon steels in this regard.

The next type is the martensitic stainless steel. This steel too, can be welded. However, one must take some precautions to make it effective. For, it generally produces extremely hard and brittle zone attached to the place of welding. So, one must take a lot of care in the pre heating to make sure that there is no crack occurring there. Sometimes, people weld this steel with the austenitic steel filler rods to improve the ductility of the deposits.

Finally, there is the Ferritic stainless steel which is the worst choice in case of welding. They have excessive grain growth, they lack ductility and they have sensitization – all three hampering the welding properties of the type.

Article Source: http://EzineArticles.com/5766755

Welding Techniques for Fabrication

Welding Techniques for Fabrication

In industry most of the materials are fabricated into the desired shapes mainly by one of the four methods, casting, forming, machining and welding. The selection of a particular technique depends upon different factors which may include shape and the size of the component, precision required, cost, material and its availability. Sometimes it is possible to use only one specific process to achieve the desired object. However, more often it is possible to have a choice between the processes available for making the end product. In the latter case economy plays the decisive role in making the final choice.

CASTING

Casting is perhaps the oldest known method of giving shapes to metals and alloys. When found suitable, it is the shortest route from the ore to the end product and usually the most economical. Through these days techniques have been developed to cast almost all metals and their alloys but still there are certain specific materials which have very superior casting properties, for example grey cast iron.

FORMING

After casting followed the forming process in which the metals and their alloys are given desired shapes by the application of pressure, either by sudden impact as in the case of hammer blows or by slow kneading action as in hydraulic presses. Mechanical working of a metal below its recrystallisation temperature is called ‘Cold Working’ and that accomplished above this temperature is known as ‘Hot Working’. Both hot and cold working (and forming) is practised extensively in the industry.

MACHINING

It is the process of giving the desired shape to a given material by removing the extra or unwanted material by cutting in the form of chips. The cutting tool material is by necessity harder and stronger than the material to be cut. The machining processes commonly employed are turning, milling, drilling, shaping, planning, reaming, boring etc. Through lathes and milling machines were used in connection with watch making even in the fifteenth and sixteenth centuries but most of theses processes were introduced into the high volume industries in their present forms for making stream engine parts in the late nineteenth century but have come of age in the present century.

WELDING

Welding as it is normally understood today is comparatively a new corner amongst the fabrication process through smith forging to join metal pieces was practised even before Christ. Through there are a number of well established welding process but arc welding with coated electrodes is still most popular welding process the world over.

These days different welding machine developed for different welding process like arc welding machine, MIG welding machine, TIG welding machine, welding rectifier, spot welding machine, plasma cutting machine and also portable welding machine like inverter welding machine (IGBT welding).

Arc welding in its present form appeared on industrial scene in 1880’s. Through there are conflicting claims about the inventor of this process but very often it is attributed to a Russian named Slavianoff who is claimed to have patented it in 1881. Arc welding machine, however, was not accepted for fabrication of critical components till about 1920 by which time coating for electrodes had been well developed. However, the demand for large scale production of heavy items like ships, pressure vessels, construction of bridges and the like provided the necessary impetus for welding to come of age and the Second World War firmly established it as the major fabrication process.

Welding which is a process of joining two or more parts of material (s) through provides a permanent join but does normally affect the metallurgy of the components. It is therefore usually accompanied by post weld heat treatment (PWHT) for most of the critical components.

Most materials can be welded by one process or the other. However, some are easier to weld than others. To compare this ease in Welding a term “Weldability” is often used. Weldability of a material depends upon various factors like the metallurgical changes that occur due to welding, changes in hardness in and around the weld, gas evolution and absorption, extent of oxidation, and the effect on cracking tendency of the joint. Depending upon these factors plain low carbon steels have the best weldability amongst metals. Quite often materials with high castability usually have low weldability.

Welding process widely used in the industry include oxy-acetylene, manual metal arc or shield metal arc (SMAW), submerged arc welding (SAW), metal inert gas (MIG), tungsten inert gas (TIG), thermit welding and cold pressure welding. Most of these processes have special fields of influence like resistance welding is popular with the automobile industry, thermit welding for joining rails in situ, MIG welding is particularly suited for welding of low carbon steel structures as also welding of stainless steels and aluminium, TIG welding is more popular with aeronautical and nuclear industries, SAW welding for ship building, cold pressure welding by food processing industry, and the like. However, SMAW or stick electrode welding and oxy-acetylene welding processes are the general purpose processes with a wide range of applications.

Some of the typical applications of welding include the fabrication of ships, pressure vessels, automobile bodies, off-shore platforms, bridges, welded pipes, sealing of nuclear fuel and explosives etc.

Article Source: http://EzineArticles.com/7745722

Laser Welding Machines

Laser Welding Machines

Laser Workstations From OR Laser: Perfectly Designed for Your Needs

HOT WELDING

Laser-welding systems are now used in many fields to contactlessly make high-quality joints. So they result in flawless seams in metal plates, plastic components, jewelry, and even building – components.

The laser welding equipment is available from OR-Laser meets all of these demands while flexibly permitting highly customized work. So these systems are therefore ideal for virtually any manufacturing task. So the professional-grade laser welding equipment presented in our catalog includes ten different systems that are tailored to meet specific industrial needs.

Laser Welding applications

Applications for Laser Welding Technology

OR-Laser is the best source for a wide variety of professional the laser-technology, so including equipment for precision laser welding and much more. So compared to conventional laser welding technology, laser beam – welding offers enormous advantages and is currently being used in many different fields. So the range of welding lasers extends from – point or area laser beam welding to within tenths of millimeters in the dental & jewelry industries.

When welding with a laser, so there are many forms and a number of possibilities. So some examples include spot, seam, and direct welding. And with laser plastic welding, plastics may be welded & fixed to each other. And another popular method of laser – welding is welding with a scanner, so in which the piece to be processed can be positioned as desired. And each laser system makes it possible to join – components of widely differing materials and combinations. So the benefits are concentrated heat control, high-strength joints with high weld depth, small weld width, & low thermal stress.  So these processes can be automated and monitored online.

Ordering Laser Welding Services and Products With OR Laser

OR Laser is proud to offer a wide variety of custom laser welding – services & industrial laser systems for sale around the world. And with this extensive experience in the research and manufacturing of the laser-machines, we are guaranteed to be the ideal choice for your industrial welding needs. Our laser beam welding-equipment undergoes extensive testing before it is approved to be added to our product-line, and you can be sure that you’ll receive only the highest-quality machines.

This laser welding solutions are used by a wide range of consumers, from the automotive-industry to the dental field. And whether you’re looking for professional consultation services and top-quality equipment, OR Laser has the answer.

Laser cladding with wire

In this process, and the laser beam melts the wire and the base metal, so the melt bonds permanently & resolidifies until a small rise remains. And when the individual welds overlap-precisely, so the desired shape is applied bit by bit.

Laser-cladding with wire is used for the repair of components & functionalizing of surfaces. So this process is particularly economical, clean, and rework is limited to a minimum. And various welding wires are available as filler materials. So this makes it possible to apply material of the same type / to create functional layers according to the requirements for the coating.

1: Laser beam 

2: Wire 

3: Work piece 

4: Application

Laser cladding with powder

Whether it is for design changes or repairs, so laser-cladding with powder upgrades surfaces as if they were cast from one customized, and industrial mold.

With laser-cladding with powder, so a filler metal powder coating is welded onto an existing component with a laser. And a professional looking layer, without pores or cracks & with little mixing & a small heat affected zone, and results.

This additive manufacturing process gives the components higher strength & increases the load capacity. And thanks to laser cladding with powder, repair instead becomes more cost effective, because as worn components can be renewed-exactly at the stressed parts.

Laser cladding with a powder-coating is not only a way to save money, and but it is also an excellent way to save time that would otherwise be spent manufacturing replacements. And the remaining material volume from this form of metal cladding shows no deformation & can keep its original properties. And through the use of metal cladding with lasers & a powder coating, components can be returned to operation quickly.

See the process of laser Cladding with Powder at work

1: Laser beam 

2: Powder feed 

3: Work piece 

4: Application

Our laser systems for sale that are recommended for additive manufacturing

EVO MOBILE

The EVO-MOBILE system is an excellent option for laser cladding with a powder coating in an open workstation. So some of the top features for the EVO MOBILE model include auto weld, high pulse peak power, an high pulse peak power intern video function, and touch screen technology too. And this all of these features are packed into a compact size to eliminate the need to have a large workspace for laser-cladding with powder.

LRS EVO

The LRS EVO model is another compact laser-welding-system. And like the EVO Mobile model, so it is ideal for an open welding workstation. And features of the LRS EVO include two Z axes, a teach-in function, simple-operation, range ability, motorized X/Y and Z travel, & a large table capacity of 350 kg.

LASERCAB

LASERCAB is a laser-welding-system that is designed for precision. And with the system’s ability to change the diameter of the laser beam during welding, so it offers a lot of flexibility. And other features include touch screen technology, integrated fume extraction, auto weld, X/Y & two Z axes, & a table load capacity of 250 kg. And this system is recommended for busy-production environments with heavy traffic.

ROBOLASER

The ROBOLASER model is packed-full of possibilities for laser cladding processes. So along with cladding ability, so this equipment also performs welding, cutting, & hardening. And other benefits include quick & short cycles, so a large selection of filler materials, low thermal stress, high hardness, & no structural damage.

Laser plastic welding

Today, laser-plastic-welding is replacing other joining techniques such as gluing & ultrasonic welding in many manufacturing & industrial fields. So the modern joining process for plastics is highly flexible & free of particles & solvents, & it provides high strength connections without marking or damaging the work surface. So plastic laser welding is invaluable when precise control or accuracy is needed to protect for the vital internal components, this can be used to successfully weld-plastics even when faced with challenging geometries.

With this illustration, you can see the process of laser plastic welding at work

1: Laser beam 

2: Transparent plastic 

3: Absorbed plastic 

4: Diffusion zone 

5: Joining pressure

Laser welding plastics utilizing the laser transmission welding-method joins two thermoplastic plastics, so a transparent plastic & an absorbing joining partner. And the laser beam penetrates the upper, laser transparent component and melts the lower, so laser absorbing component, and which then bonds with the transparent plastic. So when done properly, this creates a leak free, and secure weld.

And with this type of overlapping welding, and the weld is generated on the inside of the component without the release of particles. So it creates a nearly invisible, optically high quality weld with opaque components. And the local heat input with the laser has a minimal impact on the components, welds can be created even in the immediate vicinity of electronic-components. So because laser plastic welding creates a weld without the need for solvents, it reduces industrial waste & saves on cost, so making it a green solution for manufacturers.

There are four main techniques used in laser plastic-welding

  • Contour welding: Used for welding three dimensional / large parts, contour welding moves the laser in a single pass along the welding joint.
  • Mask welding: Laser welding plastic with this method utilizes a wide beam that moves over the entire surface being welded, with a shield protecting areas where welding is not desired.
  • Quasi-simultaneous welding: This technique utilizes a small beam that makes several passes over the welding joint.
  • Simultaneous welding: Multiple beams pass simultaneously over the welding joint.

For more than 20 years, OR Laser has been at the vanguard of laser technology and innovation. Our plastic-welding services and equipment are industry-tested, perfect for any professional need, and among the best available for sale today.

Browse our selection of laser plastic-welding equipment

Precise, Cost-Effective Production

Achieving strong and visually flawless seams is increasingly important in many production processes. And laser welding systems from OR Laser deliver the precision and efficiency required for large-scale industrial applications. What’s more, we offer a whole range of equipment from which companies of all sizes can pick the system that best suits their requirements.

Laser Welding Systems from OR Laser

OR Laser develops both mobile also stationary laser welding systems that consistently deliver top quality, so whether you work with metals or plastics. Smaller companies and those requiring mobility can opt for the EVO MOBILE, which features a compact, portable design. For midsized companies is ideal for making smaller and intermediate-sized molds, for example. For maximum flexibility, the HTS MOBILE is a mobile solution crafted to handle anything from small to large projects.

No matter which OR Laser system you can choose, you can count on outstanding quality. Each system presented in our catalog comes with a unique selection of specific and general-purpose functions. The compact PICCOLASER, for example, is a small, highly mobile unit that’s ideally suited for jewelers, goldsmiths, and dental technicians.

At the same time, it’s equipped with easy-to-use capabilities that are shared by many of our other meticulously engineered units: joystick control, motorized travel in X/Y/Z, high-pulse peak power, and more. For full versatility, the ROBOLASER is one of our most flexible systems. It’s a multifunctional triumph of ruggedness and precision with welding, cutting, hardening, and cladding functions.

source: https://www.or-laser.com/en/laser-welding-machine/

A Closer Look at Metal Fabrication Welding Process

A Closer Look at Metal Fabrication Welding Process

Metal fabrication welding has become an industry in itself with many fabrication shops operating all across the world to provide products that are required in various important industrial sectors. Among the various projects that an efficient service provider dealing with metal fabrication provides are making loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

The entire process of welding begins with preparing shop drawings, which is sometimes provided by the customer needing metal fabricated parts. Or sometimes the job is also entrusted on steel detailers. This is used as a reference point in the final manufacturing process. The CNC machines are programmed accordingly by the manufacturing engineer expert in the process of welding.

A fabrication provider may use many raw materials for manufacturing their products and this may range from plate metal, welding wire, castings, and various other types of fittings. The total fabrication involves many different steps like cutting and burning, forming, machining, welding, and then the final assembly.

Different fabrication shops use different methods for cutting metals to the required size, and they use a variety of tools for the purpose. Shearing is the most common method used in cutting any material as it is very effective and can get the work done in no time for all types of metal fabrication welding. The tools used in this method may range from special band saws equipped with blades, waterjet cutters, plasma and laser cutting tables etc. and many more.

Of all the steps in metal fabrication, welding is the most important especially if the metal used is steel. As soon as all the parts required for the project are machined, they are assembled and then welded properly for the final product. Proper care should be taken during welding so that no loose parts are left behind or there should be no welding of two wrong parts. Proper temperature should be maintained so that there are no unwanted errors in the final product.

Use custom fabricated metal only from experienced and certified user and ensure greater productivity whatever your area of operation!

I am a registered professional engineer & certified metal fabrication welding service inspector working from the past ten years. I am passionate about writing on prototype machining service industry and wish to share what I has learned from my experience.

Article Source: http://EzineArticles.com/5308482

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Machining Turning and Milling

You can trust our machinists to create top quality parts for your project using a variety of methods.

Reliable Machining & Milling Services in Billings, MT for Projects of All Sizes

In our machining department, we strive for top notch quality in all of our parts. Our machinists have a large array of knowledge and experience, whether it is turning parts on the lathe or machining them on the milling machine. Whether you just need holes drilled and tapped or your project is more complex, we can accommodate your needs in order to achieve the end product that you desire.

Get Quality Workmanship from Our Machine Shop in Billings, MT
Billings Machine & Welding takes pride in the quality and quick turnaround for the work that our knowledgeable staff puts out. We are pleased to help you in any manner that we can to provide whatever you may need to get your project accomplished.

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Welding and Fabricating

Need a project welded or fabricated? We use a variety of techniques to complete your project.

Take Care of Your Project with Quality Welding Fabrication in Billings, MT

In our welding and fabrication department, we are able to work on a huge array of different welding processes. We can offer MIG, TIG, stick electrode, and, of course, brazing and silver solder. We weld on many different metals and are available to help you with your welding and fabrication needs. We look forward to working with you.

Get Quality Workmanship from Our Machine Shop in Billings, MT
Billings Machine & Welding takes pride in the quality and quick turnaround for the work that our knowledgeable staff puts out. We are pleased to help you in any manner that we can to provide whatever you may need to get your project accomplished.

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Drivelines

We have a driveline technician to help you with your driveline manufacturing and rebuild needs.

High Quality Driveline Builds & Manufacturing in Billings, MT

We take pride in each driveline that we work on or manufacture. Our driveline technician is very diligent when it comes to how the driveline is manufactured. From removal of the old equipment—including u-joints, yokes, slip yokes, spline shafts, or tubes—we carry all of the replacement parts and equipment needed to get the job done right. After every build or rebuild, we then put the driveline into our balancing machine to ensure a top notch product that performs well.

Get Quality Workmanship from Our Machine Shop in Billings, MT
Billings Machine & Welding takes pride in the quality and quick turnaround for the work that our knowledgeable staff puts out. We are pleased to help you in any manner that we can to provide whatever you may need to get your project accomplished.

Metal Fabrication Welding – How to Get Unsurpassed Quality Products

Metal Fabrication Welding – How to Get Unsurpassed Quality Products

Metal fabrication welding is an integral part of the entire fabrication of metal process. It helps in providing services to an impressive array of processing technologies. Apart from welding, some of the other services the metal fabrication industry can offer are CNC punching, laser, CNC forming, rolling and hardware additions. Apart from these, for offering the best final additions, a Metal Fabrication Welding firm should also manage other facilities like painting, plating and so on.

Among the different metals and metal alloys that require fabrication welding firm for various welding forms are stainless steels, carbon steels and aluminum. The various technologies, which any quality firm brings to the table, include MIG, TIG, MMA and Brazing. Some of the metal fabrication welding projects include stands and tables for TVs/LCD TVs, stands for tabletop machinery, food packaging machine etc. The various fabrications need in hotel equipment category includes trolleys, working cabinets and shelving and various high-precision metal components etc.

Drive production efficiencies with advanced technologies is the basis of welding in fabrication process today. One of the most used techniques in this process is the arc welding method. It is nothing but the use of an electric arc created between an electrode and the base material used to melt the metals at the welding point. The current can be either direct (DC) or alternating (AC) current, and the electrodes can be consumable or non-consumable. A quality team can offer both conventional and hybrid arc systems, and is highly skilled in the entire arc welding, surfacing and cutting technologies.

Among the various industries that use fabrication welding processes are construction, consumer goods, defense, energy and transportation industries. In the construction segment, this is used to in heavy construction and repair equipment, mining and off-highway vehicles etc. In the consumer goods, you would find this used among medical manufacturers for developing smaller, lighter, safer medical devices that meet industry demand for higher product quality, reduced cost and greater production efficiencies. Again, in packaging manufacturing they are used to produce polymers, plastics, and adhesives.

Hence, metal fabrication welding is important in all manufacturing and service industry sectors.

Article Source: http://EzineArticles.com/5720641