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. These advances don’t mean arc thermal spray is any less valuable. Thermal spray certainly isn’t the cure-all for everything, but each process has a specific fit in the coating world. Among many things, twin wire arc thermal spray is great for dimensional restoration, sacrificial corrosion coatings, custom alloy coatings, and bearing surfaces. Arc spraying is also fast and economical, which can translate into faster turnaround and better margins. 

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.

Keeping railways safe and running efficiently has always been vital. What’s new are the welding and refurbishment methods by which this is being achieved.

Fabricating a project that uses more than 1500 tons of steel or welding 60-ft joints on beams and trusses for some of the largest buildings in New York City may seem stressful. Yet to the guys at Orange County Ironworks (OCI), that’s just an average day. Working in tandem with its sister company, Gabriel Steel Erectors, OCI is one of the biggest players in the city for the fabrication and erection of structural steel on both new structures and retrofits of existing buildings.

Redefine your capture zone with exclusive Miller® ZoneFlow™  Technology – a weld fume capture distance that’s up to five-feet from the arc – compared to traditional systems that require the hood to be placed within 12-18 inches from the arc for effective fume capture. 

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.

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.

Welding crafts are great decorative items. They’re durable, unique, and a conversation piece for your home. You can even give these handmade gifts to your friends and loved ones. Shanen L. Aranmór, founder and chief wellness welder of Weld Like a Girl^TM, Yuma, Ariz., created a fun taco project designed for summer camp welding classes at AstroCamp in Idyllwild, Calif. And who doesn’t like tacos? Here, she offers her expertise on how to weld these decorative and unique tacos with a taco stand.

Augmented reality has recently taken the forefront and is being used more and more in training programs across a variety of industries. The initial reaction is often the same: Isn’t it just a fancy toy?

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.

Q: I weld nuts to hot-stamped parts and am having difficulty getting consistent results. This includes parts where the nuts appear welded to the part, but sometimes pop off in transit to our customer. We also get inconsistent push-out test results. How come? I have asked this question many times and have gotten many different answers.

Q: I weld nuts to hot-stamped parts and am having difficulty getting consistent results. This includes parts where the nuts appear welded to the part, but sometimes pop off in transit to our customer. We also get inconsistent push-out test results. How come? I have asked this question many times and have gotten many different answers.

An outdoor barbecue grill is a great project for beginner welders. It’s practical and the materials aren’t very pricey. Here are instructions on how to fabricate your own open-framed BBQ pit.

Q: I have three different welding machines in my plant along with several robotic transguns. A couple of my machines are 50-kVA press machines and my transguns are 100 kVA. Why can my 50-kVA machines produce up to 35-kA secondary current, but my transguns only go as high as 18–20 kA?

Gas metal arc welding (GMAW) is one of the most-used welding processes in the world. Advancements in GMAW-related equipment, such as the ones highlighted here, keep it at the forefront of welding technology. 

Attracting and proficiently training welding students on a limited budget can be challenging, which is why Miller® developed MobileArc™ – an Augmented Reality Welding System that offers a convenient option that fits most budgets. Its highly-realistic, portable, and intuitive design is simple enough for students to self-learn so instructors can maximize efficiency in the classroom.

Several different wire feeding methods can be used when narrow-groove-gas-metal-arc-welding heavy-section materials that have nearly square butt configurations and minimal groove widths of approximately 13 mm (½ in.).

From robot kits to solder paste, this piece offers something for both the hobbyist and professional solderer.

Resistance welding (RW) is a thermo-electric welding process in which the weld is made by a combination of pressure and current. The process involves the joining of metals by applying controlled pressure and passing current through the metal area to be joined. There are several different forms of RW (e.g., spot, seam, projection, single-sided, bonding, cross wire, micro, flash, and upset welding) that differ primarily by the types and shapes of weld electrodes used to apply the pressure and conduct the current.

Resistance welding (RW) may not generate the volume of fumes created by gas metal arc or shielded metal arc welding, but capturing what’s produced during this process must still take place.

Hypertherm, a U.S. based manufacturer of industrial cutting systems and software recently introduced PlateSaver™, a new SureCut™ technology that automatically maximizes the number of parts on a plate for more profit per plate.

Welding automation technology can help junior welders perform more-challenging welds previously only performed by senior welders while also allowing senior welders to broaden and extend their careers.

The American Welding Society (AWS) has a selection of standard welding procedure specifications (SWPSs) that can be used without qualification testing. But only one is for aluminum.

Learn why these three pipe and tube products are a cut above the rest.

An industrial robot can achieve more than three million aluminum arc starts per week using a push-only wire feed system. But while technology has improved the reliability of such systems, some proven tips should be followed.

Computer numerical control (CNC) machines play an essential part in countless manufacturing applications. They build these machines for processing a variety of materials, such as metal and plastic, and shape them into the required forms. Advanced technologies have also enabled CNC machines to become more powerful by featuring more axes for greater precision and enhancing operational efficiency. As CNC machines continue to evolve, they require more complicated components, faster operating speed, and greater attention to the machines’ operation status to avoid system downtime.

3M Xtract™: Sanding, reimagined.

Multipass welding increases critical weld strength in applications where failure could be catastrophic, including heavy-duty structural fabrication and pipelines and pressure vessel fabrication. Proper preparation and cleaning are critical for attaining quality welds.

Learn about handheld tools and automated systems that can help you cut, shape, and remove material fast and efficiently.

Welders depend on a multitude of tools to achieve their jobs, but the most important of these tools is personal protective equipment (PPE). Ranging from respirators to flame-resistant clothing, these new PPE can safeguard welders against the hazards present in the workplace.

Even experienced operators make mistakes that can impact cut quality and consumable life. Many of the most common plasma-cutting and consumable issues can be avoided altogether by following the eight tips outlined in this article.

A significant value stream can be achieved by recovering brazed components after their life cycle.

The advantages of using grinding wheels are widely known. However, when grinding wheels that spin at thousands of revolutions per minute (RPM) are damaged or misused, they can break into bullet-like fragments, leading to injury. Grinding safety is a vast subject, with seemingly limitless tips, but the following offers just a few key guidelines to keep top of mind.

Electrogas welding is an arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. Continue reading this article to learn much more, including advantages and limitations.

Transfer modes for gas metal arc welding (GMAW) play an important role in the level of quality and productivity that can be gained in a welding operation.

Find out how using CAD models can help you create and verify modular fixturing designs for increased efficiency in the workshop.

Professional and amateur welders alike demand high-quality personal protective equipment (PPE) and gloves — and for good reason.

More than 70 years after first entering service, hundreds of vintage Chipmunk airplanes remain airworthy around the world, mainly as trainer aircraft. Repair and maintenance of many of their components remain a challenge due to lack of components as well as process temperature sensitivity. Fortunately, there is cold spray, a solid-state metal consolidation process that can be used to dimensionally restore components made of materials that are highly sensitive to elevated process temperatures.

Critical pipe welding applications often require preheating and possibly postweld heat treatment to reduce the chances of cracking. Learning different methods and proper application of welding preheat can help save time and money.

This year, IRONMAN competitors in St. George, Utah, will have more than cheering fans waiting for them at the finish line. An M-dot sculpture crafted by Rick Prazen and his son, Josh, will greet them in a roundabout near the end of the race.

Iowa-based Gail Chavenelle is proof that it’s never too late to embark on a new adventure. At the age of 50, the former school teacher became a full-time metal sculptor.

Richard Prazen, a blacksmith and metal sculptor in South Jordan, Utah, has honed this skill with more than 55 years in the welding and manufacturing industry. In his hands, pieces of metal come to life as soaring eagles and giant spiders.

To achieve long-lasting performance out of your gas metal arc gun, inspect its liners, tips and other essential components.

Gas metal arc welding (GMAW) is an arc welding process that uses an arc between a continuously fed consumable electrode and the weld pool. The process is used along with shielding from an externally supplied gas and without the application of pressure.

Highlighting the strength of this market, and the high demand for arc welding products, 2020 and 2021 saw the release of many products designed to simplify arc welding.