Gun AnglesClick image to enlargeFlux Cored Arc Welding (FCAW) has been widely used for a number of years and is known for its high deposition rates and exceptional mechanical and chemical properties, perfect for structural steel, pipeline welding and other similar applications. 

 

Tiffner Johann, welding technician for Fronius in Western Canada, identifies four common issues using flux cored wire welding in 5G (pipe fixed) position.  

1. Gun Angles
A common problem is using the wrong welding gun angles in pipe welding for manual and automated. The gun angle should be straight (90°) on the pipe going from six to 12 o’clock positions to avoid welding slag build-up, mostly on the top of the pipe. Using a push angle gives you a better-looking weld profile, but welding slag inclusions are more likely, especially if you’re not speeding up the welding carriage on the top of the pipe. 

wide capsClick image to enlarge2. Wide Caps 
If the fill pass is too wide and the wire is riding up too much on the side wall, the weld drops down on the edges because the support of the welding slag is lost.

3. Synchronizing Parameters 
“Parameters for the carriage speed, weaving speed and weaving width should be synchronized to get a good weld. They are set independently and, for example, if the weaving speed is too low, it can result in a rough weld appearance and rework will be required before the next welding pass. This photo is an example of a good and bad weave, both of which are made in the three o’clock position.  

4. Cap Passes
Trying to fill too much with the cap pass could result in undercut, bad overlap, and the weld could get sucked in.

Maintaining your MIG gun and welding costs, by Grant Peppers

Selecting the right MIG gun for your welding application, and maintaining it properly, is just as important to your overall productivity as any other part of the welding operation.

Welding robotics

Understanding the benefits and building the case for the investment

By Brian Doyle, sales manager, Miller Welding Automation

The thought of converting to an automated welding system can be intimidating, even to the point that it causes the decision makers to disregard the process altogether.

Simplify TIG torch installation

by Keith Werkley, regional sales manager, Weldcraft

 Just like any part of the TIG welding process, learning how to assemble and install your TIG torch properly may seem intimidating at first.

Robotic tube cutting and profiling

Vernon Tool, a Lincoln Electric company, has developed a new robotic tube cutting and profiling system, the Vernon Tool Razor for high production tube and pipe fabricators in heavy fabrication, agricultural, construction, vehicle and tube frame manufacturing.

Better welding performance for sub arc apps

ESAB Welding and Cutting Products’s new Aristo 1000 AC/DC power source for sub arc welding is an inverter power source that can be connected to three-phase input voltage supply (from 380 to 575V at 50 or 60 Hz).

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