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Appleton, WI, United States

Poirier D.,Miller Electrical Manufacturing Co.
Manufacturing Engineering | Year: 2014

Pairing galvanized steel with metal-cored wire offers speed and performance benefits in automotive welding applications. Because galvanized steel offers thinner gages while still providing high strength and corrosion resistance, the material can help automotive manufacturers reduce total weight by hundreds of pounds in some cases, to help meet the increasingly strict fuel economy requirements. Surface porosity on galvanized steel is a common issue that is regulated by American Welding Society (AWS) standards, the travel speed used during the welding process directly impacts the presence of porosity. In addition to porosity, other potential challenges when welding galvanized steel include risk of burn through due to the heat input, and the presence of silica islands in the weld, especially those that may break free after the e-coat or paint process or those that adhere to the toes of the weld, which can be a potential source of rust later on in a the life of the part. Another issue for manufacturers to consider when converting to galvanized steel is the weld fume created during the process. Metal cored wire carries higher current densities making it possible to put more weld metal in a joint in less time during the welding process. Source

Ryan J.,Miller Electrical Manufacturing Co.
Welding Journal | Year: 2014

Two common practices in pipe fabrication that offer many benefits for productivity, quality, and operator comfort are preheating and rolling the pipe while welding. Preheating pipe helps reduce the potential for a failed weld, and it is necessary for meeting code or quality requirements when the pipe is chromemoly, more than 1 inch thick, or stored in cold environments. Induction heating of pipe has been around for decades, but it was not well suited for roll-welded applications due to the heating cables that had to be wrapped around the pipe. Rolling induction technology is designed for easy and quick setup and repositioning. The hinged arm and rolling inductor mount on a standard pipe stand, so the welding operator can align the induction head on the pipe. Source

D'Arcy A.,Miller Electrical Manufacturing Co.
Welding Journal | Year: 2014

Metal-cored welding wire formulated for galvanized steel is capable of providing faster travel speeds, which lowers the heat input. Combined with a pulsed gas metal arc welding (GMAW-P) process, it can help improve productivity and efficiency on this material while also producing high weld quality. It is a type of tubular wire consisting of a metal sheath filled with metallic powders, alloys, and arc stabilizers. Galvanized steel has a protective layer of zinc on its surface, so the material offers excellent corrosion resistance even at thinner gauges. The thinness and zinc coating of galvanized steel are characteristics that provide many benefits, but they can also be source of porosity and melt-through. The new metal cored welding wire is designed to weld at 40 inches/min in robotic applications. The faster travel speed and lower defect rates can help automotive manufacturers increase throughput, reduce expenditures related to work and save time and money. Source

Cuhel J.,Miller Electrical Manufacturing Co. | Benson D.,Hobart Brothers Co.
Welding Journal | Year: 2012

The basics of welding stainless steel tube and pipe for applications ranging from high-purity food and beverage, pharmaceuticals, and petrochemicals, are discussed. When prepping stainless steel, dedicated brushes, files, and grinders should be used that never touch carbon steel or aluminum. Filler metals with an 'L' designation, such as ER3O8L, provide a lower maximum carbon content, which can help retain corrosion resistance in low-carbon stainless alloys. Straight argon is recommended for gas tungsten arc welding (GTAW) of stainless steel tube and pipe. Precisely controlled metal transfer with modified short-circuit GMAW provides uniform droplet deposition and makes it easier for the welder to control the weld pool and, thus, heat input and welding speeds. A modified short circuit GMAW process presents an improvement over traditional short-circuit GMAW in that the welding system anticipates and controls the short circuit, then reduces the welding current to create a consistent metal transfer. Source

Rappl J.,Miller Electrical Manufacturing Co.
Manufacturing Engineering | Year: 2015

Remote control welding technology allows welding operators to set welding parameters at the joint without the need to carry, route, troubleshoot, and maintain expensive control cables, while delivering consistent welding performance. The single set of welding parameters enables the welding operator to stay where the welding is done, reducing the need to access controls in inconvenient locations. Remote control welding technology also enables the welding operator to set welding parameters at the arc without a control cord and without the using wireless controls that require batteries or line-of-sight for operation. Source

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