Welding is a cost-effective manufacturing process. However, several factors can significantly increase or reduce the cost-effectiveness and productivity of a welding project. These range from operational efficiency to the use of consumables.
In this article, we will go through 10 ways to significantly reduce welding costs and boost the productivity of welding projects.
1. Avoid Overwelding
Overwelding occurs when a weld is larger than it needs to be. This is a common occurrence in the welding industry, especially with inexperienced welders. An overweld may result when there is no specified weld size in a design, when there is no fillet weld gauge, or when a big weld is created just to play it safe.
Overwelding is a significant resource drain; it uses more arc time, labor, shielding gas, and filler metal, which leads to higher costs. To put this waste into perspective, consider a 1/4″ overweld instead of a required 3/16″ weld: The overweld results in a 78% increase in both weld metal deposition and arc-on time. This goes up to 177% when the overweld is 5/16″.
The construction industry is responsible for the creation of all kinds of structures with varying sizes, levels of complexity, and uses. From simple, small structures such as family homes to large, complex ones like bridges, dams, and manufacturing plants.
Structural integrity and durability are the most important considerations in this industry. This is why the construction industry employs a very large quantity of metals. In the United States alone, more than 40 million tons of steel are used annually in the construction industry. The majority of this quantity is used to create structural frameworks. This is where welding plays an indispensable role in construction.
Welding technologies are widely usedin the construction industry, mainly for the fabrication of structurally sound metal frameworks for by fusing various metals components. It also used to create and maintain non-structural components. Some of the welding used for construction is on pre-fabricated in a shop environment while other parts of the welding process are done on-site.
Applications of Welding in Construction
Construction comprises numerous industries, including transportation, oil and gas, telecommunication, power, manufacturing, many others. The construction industry is very broad & diverse and is divided into three major sectors which differ by the type of structures they create. These sectors are Building, Infrastructure, and Industrial.
The application of welding, is crucial to all three sectors.
In the midst of the current global pandemic, massive challenges to public health and safety have impacted the global economy resulting in significant levels of unemployment in many countries. While small businesses are scaling down or declaring bankruptcy, critical industries like manufacturing are stepping up to meet the challenges of the pandemic. Rapidly deployed, innovative solutions are helping provide much-needed medical devices, services, and supplies.
Red-D-Arc Innovates with Robotic Welding
Since systems are at full capacity, custom metal fabrication and welding equipment industries are also in high demand to support production for medical devices and diagnostic equipment. Throughput is the most critical key performance indicator (KPI) for manufacturers, and an efficient rate of production requires consistency and high-quality output.
The oil and gas industry plays a very important role in the global energy supply as well as the world economy. Many technologies are crucial to the existence and functioning of this multi-billion dollar industry. One of these is welding.
The oil and gas industry utilizes various highly complex infrastructure such as rigs, pipelines, platforms, plants, and facilities. The majority of these infrastructures are created using welding technologies. Welding is critical in oil and gas operations both for the construction of new projects and for the maintenance of existing facilities.
Applications of Welding in Oil and Gas
The oil and gas industry is divided into three major stages of operation. These, which can be referred to as sectors, are Upstream, Midstream, and Downstream. Welding is widely used across all these sectors and its applications can be classified accordingly.
Whether you’re working in the petrochemical, manufacturing or food and beverage industry, plant shutdowns are inevitable. Plant maintenance is vital to optimizing peak performance of a facility to ensure profitability, safety and regulatory compliance.
From a routine plant shutdown and maintenance period, metrics such as quality, schedule and cost can be measured and planned in advance. However, exceptions such as the global outbreak of COVID-19 global pandemic can pave the way for unexpected maintenance opportunities. In a move to contain the virus spread, companies close up shop temporarily to follow government mandates, protect their employees and take advantage of the opportunity to perform deep-cleaning routines using technologies like dry ice blasting on their factories simultaneously.