Miller’s ArcReach air-cooled induction heating system is designed for preheat and bake-out applications at temperatures up to 600 degrees Fahrenheit (315°C), without requiring cooler and coolant. Temperature control settings can be manually programmed or uploaded via USB stick. All heating data is recorded automatically and can be saved for quality control and documentation purposes.
“Achieve critical temperatures quickly and hold them steady over long periods of time”
Red-D-Arc’s latest customer success story highlights the benefits of using induction heating in rotating equipment applications.
A client contacted Red-D-Arc to inquire about the use of induction heating to remove a coupling hub from a motor shaft. The hub was 12 inches in diameter and roughly 4 inches thick.
The overall work scope was straightforward: the client needed to remove an old motor and replace it with a new motor. The coupling hub had to be reused, so the hub would need to be removed from the old motor and installed on the new one. Two things made this job challenging: the location and the time limit. The work was to take place on an offshore platform. Use of an open flame was not an option, as it would have led to a safety violation. (more…)
Blowout Preventers Increase Safety for Drilling Operations
A blowout-preventer (special valve or device used for preventing blowouts on oil and gas wells) which had been stuck together for 9 years is finally separated with the quick application of a Miller induction heating system from Red-D-Arc.
Erectors can save cost and time by taking this welding technique in-house
Large steel erection projects commonly require heat treatment for welding because of the thick materials used in structural steel construction. Proper implementation is critical; so often this work is outsourced. The perceived level of expertise to perform this work can make the prospect of using in-house personnel daunting. However, most welding contractors are actually fully capable of performing on-site heat treatment operations.
The two primary methods for heat treating metal are preheating and post-weld heat treatment(PWHT).Preheating is the process of heating the base metal to a specific temperature prior to welding to minimize the temperature difference between the welding arc and the base metal. This process helps to reduce internal stresses that occur as substantial temperature differences between the weld and the base metal normalize, which can cause cracking and distortion. Slowing the cooling rate also allows hydrogen to escape from the weld, which minimizes the potential for cracking.
Applications and Advantages in Tank Fabrication and Maintenance
In the fabrication of storage tanks, as in most other welding applications, there are two crucial processes that storage tank fabricators must carry out to ensure the final quality and durability of the tanks. They are weld preheating and post-weld heat treatment.
Preheating involves heating the material to be welded to a particular temperature before welding. This process reduces shrinkage by minimizing the temperature between the arc and the base material. It also removes moisture, lowers hydrogen, and slows the weld cooling rate. These reduce the risk of cracking, brittle welds, and failure of the welds. Preheating is crucial for storage tanks as they are to withstand high pressures during operation.
In welding, like in many other manufacturing and fabrication processes, the process is not complete until the necessary post-processing has been carried out. Post-weld operations are usually performed for reasons such as improving mechanical properties, relieving stress, and improving aesthetics. The two most common Post-weld operations are Post-Weld Heat Treatment (PWHT) and Finishing.
Post-Weld Heat Treatment
During welding, the welded materials are exposed to very high temperatures that can cause micro-structural changes in them. Also, residual stresses build up in welded materials when they are allowed to cool naturally. If left unaddressed, these stresses and structural changes can severely compromise the mechanical properties of a material and can lead to failure during use. To prevent this, PWHT is required for welded parts. There are two major types of Post-weld heat treatment and they are as follows. (more…)
The manufacturing industry is in distress. There is a shortage of skilled talent and this gap is only widening. While manufacturing companies are able to make goods faster and cheaper than ever, there is a growing lack of skilled manufacturing employees to ensure that production continues. Industry projections from Deloitte and the Manufacturing Institute, among other industry analysts, predict that over the next decade, more than 2 million manufacturing jobs will go unfilled across the U.S.
This decline in skilled manufacturing workers is a result of two issues:
1. A very large portion of workers at or near retirement age
2. Incoming generations that are far less interested in the manufacturing industry
Welding is perhaps one of the susceptible areas in manufacturing to this trend because of the skill welding requires. The lack of skilled welders is causing large inefficiencies in the manufacturing industry due to understaffing and also causing pay rates of skilled welders to go higher and higher. Since it does not appear that upcoming generations will have a large participation rate as welders, the solution to the problem will likely be solved by the implementation of automated welding solutions.
Automated Welding Solutions That Deliver ROI
Automated Welding Solutions Come in a Variety of Forms
Automated welding robot machines, automatic welding bugs, automatic orbital welding machines, and even automated resistance welding equipment are being used to help combat the void created by a lack of skilled welders.
Although full-auto arc welding machines are part of the remedy, they are not a panacea. Fully-automated welding solutions often require high capital expenditure, require expensive skilled programming personnel, and pose significant safety risks if not set up properly. The trade-off between the benefits of fully-automatic welding machines and their disadvantages led to the development of a new type of automated welding solution: the welding cobot.
Enter: The Cobot (a Collaborative Robot)
The name cobot is short for “collaborative robot”. The increase of cobot development and deployment is revolutionizing the manufacturing industry. Welding cobots are unique welding tools that hold many advantages over other automated welding machines, especially traditional welding robotic systems. Cobots have special mechanisms and move in such a way that enables them to require little to no safety fencing. While the potential for increased safety without extra costs is an excellent benefit, the most important benefit of cobot use in an automated welding cell is the reduced costs associated with installation and programming.
Robotic Welding Just Got Easier
Traditional automatic robotic welding machines require a high level of skill to program. Oftentimes many years of knowledge and experience are required to set up an automated weld cell; for this reason, many companies elect to hire contractors to do this work for them, adding to the already high cost. With cobots, the programming of the machine is much simpler. The programming software is engineered to be user-friendly, vastly decreasing the instruction time required to train a programmer. This not only lowers the initial costs of programming but also enables a cobot to have a high degree of flexibility. The decrease in programming time and safety equipment and the increase in flexibility typically result in a very short ROI timeline and reduce the dependency on skilled welders and automated welding robot programmers.
Red-D-Arc understands that many of our customers are not immune to the trends affecting the manufacturing industry as a whole. We know that maintaining a technological advantage is key to success. In order to help our customers fight increasing costs associated with the decline in skilled welding employees and complicated automatic welding machines, Red-D-Arc offers collaborative welding robot solutions.
Introducing The BotX-Welder: The Robotic MIG Welder Solution
The BotX-Welder is our cobot product solution for our customers. The BotX-Welder package comes with a UR10e cobot arm created by Universal Robots, a leader in cobot development. In conjunction with this robot arm, the Bot-X Welder system also comes with an XMT350 MPa MIG welder and S74 MPa Plus wirefeeder, both made by Miller Electric. A MIG welder torch and a welding fabrication table are also included to complete the cobot welding cell. While the hardware is state-of-the-art, it is the software in the BotX Welding cell that truly sets it apart. The robot arm in the Bot-X automated welding system is controlled by the Hirerobotics application, which can be used with either iOS or Android operating systems. The Hirerobotics app is much easier to use than a traditional automatic robotic MIG or TIG welding machine teach pendant.
A Welding App With All The Robotic Welding Routines You Need
What’s more is that the Bot-X Welder also comes with an expansive library of welding routines, with weld parameters made to fit almost any application. Welding can be automatically monitored and recorded through cloud connectivity. This allows remote users to view weld data from anywhere in the world as long as they are connected to the network. The cost and risks of new technologies are often high. Red-D-Arc eliminates the risk of failed robotic welding implementations by only charging our customers by the productivehour when using the Bot-X Welder. This enables users to try the machine out, use it as much as they need it, and get rid of it when it the work slows down. This probably won’t be a problem, since you’ll be able to keep customers happy with a quick rate of output and very high weld quality. The pay-as-you-go system is much easier and more cost-effective than the traditional hiring and firing of personnel.
Maintaining a technological advantage is key not only to prosperity in the manufacturing industry, it is essential to survival. As more and more efficient means of weld, production is developed and as the number of skilled welding laborers declines, the pressure is on to adapt.
Red-D-Arc has always and will continue to support our customers through industry shifts. The Bot-X cobot MIG welder system is another way we help you keep ahead of the competition.
See the BotX Welder in action live at Fabtech 2019.
There may only be one thing better than eating delicious barbecue cooked slow and low on a smoker, and that is eating some delicious barbecue that you cooked slow and low on the barbecue smoker that you made. Making barbecue smokers has long been a favorite hobby of backyard cooks and professional pitmasters alike. (more…)
ArcReach® technology is an investment that results in a lot of time saved during welding operations. With most welding equipment the operator needs to walk back and forth to adjust output voltage – sometimes over hundreds of feet – multiple times during a job. This results in hundreds of wasted hours and thousands of lost dollars over the course of a large project.
ArcReach technology enables welders to adjust the voltage settings right at the point of welding
ArcReach technology enables welders to adjust the voltage settings right at the point of welding instead of walking all the way to the power source and back. Even worse, if the voltage settings are “just good enough”, the operator might not bother making the trip, resulting in lower quality welds. (more…)
When MIG welding was first invented, it used a constant voltage source of electricity for the arc. While this method is still used today, the invention of pulsed MIG (or MIG pulse) welders has allowed welders to realize several advantages over conventional MIG welders, several are listed below:
Pulsed MIG can be used to weld thin materials. Conventional MIG welders run at a constant amperage whereas pulsed GMAW welding runs a peak and background amperage. The constant switching between these two amperages enables the welder to put out a lower overall heat input into the material. This helps prevent blowouts on thin materials.
There is less spatter than conventional MIG welders. Pulsed MIG welders use peak electrical currents to cleanly burn the wire off at a high amperage. It also employs a lower background welding amperage immediately after the peak electrical current to prevent the interaction of the electrical arc and the wire from becoming unstable. This ultimately results in a reduced amount of spatter.
MIG pulse welding is excellent for out of position welding. At the same voltage and wire feed settings, conventional MIG tends to have a weld puddle that is larger and more fluid than that of pulsed. MIG pulse welding has a more controllable puddle that prevents it from falling out when gravity is a concern during out-of-position welding. Furthermore, the reduced amount of spatter that can be achieved with this method makes it safer for the welder to perform the out-of-position operation.
Red-D-Arc Carries a Number of Pulsed MIG Welder Machines
Whether you’re looking for an EXtreme 360 MAP, a Lincoln Power Wave S350, a D325K 3+12 Diesel, or Millermatic 350P – we have it all!
The Millermatic 252 is an impressive machine that’s capable of 300A output amperage. This allows you to weld at higher output for a prolonged period of time - perfect for those longer jobs. The 252 is suitable for a wide range of industrial work and is able to go from 22 gauge to 1/2 inch steel in a single pass.
If you’re regularly welding large pieces of metal for sustained periods of time or you need a machine that’s up to the task of working in a busy shop, the Millermatic 252 should be your number one choice.
Best Features of the Millermatic 252
The 252 has the highest output of all welders in the Millermatic range, making it a fantastic choice for those who weld for a living. It’s an incredibly versatile machine that can withstand even the busiest of environments and heaviest of workloads. Whether you’re using this machine to weld stainless steel or carbon steel, the Millermatic 252 is more than capable of the task.
For welders who need to pump a ton of wire into their welds, a resilient and reliable setup is a must. Being able to weld effectively without running the risk of delays is vital in this day and age. Financial losses as a result of machine breakdowns or jams can have a negative effect on a business. Remember, it’s important to select the right welding wire for the job.
Thankfully, the Millermatic 252 has a top of the range design that has been specially engineered to prevent incidents like this from occurring. It features an aluminum dual-gear drive system that allows the machine to feed wire without the need for any downtime. There are spaces on the machine for you to store drive rolls, so the disruption to your work is minimized.
The trademarked Auto Gun Detect technology allows users to simply pull the trigger on their MIG, spool, or push and pull gun and the Millermatic 252 detects the appropriate voltage and wire feed speed of the active gun. This saves a lot of time in the workplace and can reduce your job turnaround time dramatically, especially when you’ve taken the importance of welding surface preparation into consideration.
The cast aluminium drive system feature a number of controls that make the user experience as smooth as possible, including quick-change drive rolls, and an easy to set tension knob.
The EZ-Change™ cylinder rack allows users to change cylinders with minimal fuss by simply rolling them on and off. This is another time-saving feature that serves to make your welding experience as smooth as possible.
With an impressive gun range of 15ft, the Millermatic 252 enables users to work at longer distances than most of its competitor’s machines. The length means that it’s easy to work on larger pieces of metal without the need to be constantly readjusting the placement of your equipment.
The Drawbacks of the Millermatic 252
The Millermatic 252 is quite a big machine. Consequently, it’s not really suitable to be moved between locations due to the sheer size of it. As such, it’s best suited for a shop environment. Also, the larger MIG gun can make more intricate, thin work a challenge. Despite these minor drawbacks, the Millermatic 252 is an impressive machine that can hold its own among the best on the market.
Millermatic 252 Specifications
Unit Height: 30 in.
Unit Length: 40 in.
Unit Width: 19 in.
Rated Output: 300A maximum of 200 Amps at 28 VDC on a 60% duty cycle OR 250 Amps at 28 VDC on a 40% duty cycle
Input Voltage: 220/230/240 V
Weld Thickness: The 252 is able to weld anything from 22 gauge to 1/2 inch mild steel
Wire Feed Speed Range: 50 inches per minute to 700 inches per minute
Welding Amperage Range: 30 A – 300
Texas – One of our customers was trying to heat 42” diameter pipe using pear burners so that welders could weld out the joints. Our team saw an opportunity to create a solution that would help our customer get the job done much more quickly. To make this in-the-field heating job go faster, we put together a package including a Miller ProHeat 35 induction heating system, a 60kVA generator and a DP25 power distribution panel.
Red-D-Arc provided a reliable RDA Induction heating solution to a pipeline construction and maintenance company in Houston who needed to maintain consistent temperatures for their welders to weld out joints from pipes. Our induction heating specialist supplied our customer with a portable induction heating package consisting of a 60 KVA generator, a Miller Pro-Heat 35 induction heating system, and a DP25 power distribution panel. As a cost-effective alternative to their existing propane burners, induction heaters allowed them a secure heating, consistent temperature control, increased weld time, and improved safety.
With this setup we were able to get the pipe up to 250 degrees in about 5 minutes. Our customer was able to beat the competition’s target time by over 19 hours and has been asked to quote on other pipeline work for their client. Needless to say they were pleased with the solution and the opportunity for extra work it created. (more…)
Pre-weld and post-weld heat treating is critical for many welding operations. Without proper thermal manipulation, welds and heat affected zones can have mechanical properties that are undesirable. Worse yet, inadequate heat treatment can result in cracks and devastating weld failures. While temperature and time are the primary concerns when heat treating a weld, the heating method should also be considered diligently when selecting a process. Induction heating is one of the most popular types of heat treating methods, and rightfully so. The benefits of induction heating are many, and Red-D-Arc has the equipment you need to successfully implement an induction heat treating operation for your projects. (more…)
The Millermatic 252 —sometimes referred to as the Miller 252— is an extremely popular and easy to use welder. You only need to see the reviews quoted on Miller’s product site to see how much those who use this welder like it. It can be used for metal fabrication, maintenance and repair, farm and home use as well as light industrial applications.
Capable of MIG (GMAW), Wirefeed, and Flux-Cored Welding (FCAW),this machine employs Active Arc Stabilizer technology which creates consistent power output resulting in better quality welds. The push/pull gun connects directly to the unit with no extra module required in between.
The unit detects the gun automatically and recalls the voltage, wire feed speed and timer of the active gun. There’s a panel on the front of the unit with a quick-reference parameter chart so you can quickly apply the correct settings for the consumables you are using. This welder has the highest output in its class (250 A at 28 VDC) allowing longer welding times on high-end applications. This is a very popular unit, praised for its ease of use by people who are learning to weld, hobbyists and others for whom welding is only one of many tasks they perform in a day. One user says that he taught his entire family to weld using this machine, including his 57 year old mother. Feature rich, well thought out, and easy to use, you would be hard pressed to find a better welder than the Millermatic 252.
Airgas, an Air Liquide company, is the nation's leading single-source supplier of gases, welding and safety products. Known locally nationwide, our distribution network serves more than one million customers of all sizes with a broad offering of top-quality products and unmatched expertise.