Some of the most difficult welds to make are those that require the welding of a small diameter to a plate. Gas tungsten arc welding or gas metal arc welding joints such as these require a high degree of operator skill, take a great deal of time, and can be a quality nightmare. These factors become even more troublesome when the material with the small radius being welded is in the vertical or overhead position. Fortunately, Red-D-Arc provides stud welding equipment that increases productivity, decreases the required operator skill immensely relative to other welding processes, and allows for consistent, repeatable weld quality on materials with small radii.
What is Stud Welding?
Stud welding is a fusion welding process that is commonly used for the joining of small round stock to plate. The process requires a power source, a stud welding gun, a ground clamp, and the materials that are to be welded. To carry out the stud welding process, a solid, round piece of metal, also known as a stud, is placed into the stud welding gun.
To begin, let’s establish what exactly we’re talking about when we say “biodiesel.” ASTM (American Society for Testing and Materials) has published a standard, D6751-07b, that defines what biodiesel is. We’re not talking about used cooking grease, or even commercially produced biodiesel, if it doesn’t meet this standard.
Also, the word “biodiesel” is often used to describe what is actually a blend of biodiesel and diesel fuel. (The diesel fuel sold for on-road use in the U.S. is Ultra Low Sulfur Diesel fuel, or ULSD.) The term “BX” designates the blend ratio, where “X” stands for the percentage of biodiesel in the blend. So B100 means 100%, or pure, biodiesel, while B20 means 20% biodiesel mixed with 80% ULSD.
Additionally, this article doesn’t address OEM recommendations or warranty limitations. We’re simply looking at the question from a mechanical standpoint.
So now, with all that out of the way, what’s the bottom line?
Here are a couple of snags that can show up in any diesel engine when using biodiesel:
Fuel filters may initially clog:
This applies to engines that have burned petroleum diesel for years before switching to biodiesel. Over time, petroleum diesel leaves small carbon and tar deposits in a fuel system. B100, a mild solvent, will “clean out” the fuel system, dislodging these deposits. This is a good thing, but it’s inconvenient when a fuel filter clogs with these deposits. Once the fuel system is clean (usually after burning 1-2 tanks of B100), this issue goes away. B20 and lesser blends do not have this cleaning effect.
Biodiesel begins to gel at a higher temperature than ULSD. As a general rule of thumb, the greater the percentage of biodiesel present in a blend, the higher the temperature at which it will start to form wax crystals too large to pass through the fuel filter. In extreme cold, without a fuel preheating system, all but the most dilute biodiesel blends may be impractical.
Now, let’s discuss changes in diesel engine technology.
Pre-common rail diesel engines (mostly pre-2000)
These engines work very well with B100 (as well as with lesser blends). In fact, biodiesel is often a superior fuel for these engines. It is a far better lubricant than ULSD, sharply reducing injection pump wear. Unlike ULSD, which is made up solely of hydrocarbon chains, biodiesel molecules also contain oxygen. This oxygen contributes to better combustion. Thus, even though biodiesel has a lower energy content than ULSD, some engines may actually see a slight increase in power output, with minimal loss of fuel economy when using biodiesel.
Common rail diesel engines
Rule of thumb:
Any biodiesel blend works great.
Diesel engines with common rail injection systems started showing up in the early 2000s. These systems burn ULSD more efficiently than older systems, so biodiesel’s oxygen content no longer offers any real efficiency advantage, and its lower energy content manifests itself in a slight reduction in fuel economy and power. Further, high precision common rail injection systems are “tuned” to fuel of a given viscosity, and the viscosity of B100 differs significantly from that of ULSD. This may, for example, change the spray pattern of fuel into the combustion chamber, and the end result can be an increase in soot and carbon buildup.
Engines with diesel particulate filters
Rule of thumb:
While B100 works, these engines work best with lower blends, like B20.
In 2008, the EPA started phasing in its Tier IV diesel emissions standard, which required an immediate 90% reduction in particulate matter. Diesel particulate filters, or DPFs, are exactly what they sound like – a filter in the exhaust system that captures particulate matter, such as soot. To regenerate, or clean, the filter, atomized ULSD is injected into the exhaust. When it reaches the DPF, it ignites and burns off the particulates that have collected there. To accomplish this, many engines periodically inject ULSD into the cylinder during the exhaust stroke. This ULSD vaporizes and flows through the exhaust system with the other exhaust gases. Biodiesel, however, is less volatile than ULSD. When it is injected into the cylinder during the exhaust stroke, rather than flowing out through the exhaust valve as a vapor, some of it condenses on the cylinder walls as a liquid and runs down through the crankcase. Over time, this biodiesel accumulates and dilutes the engine oil. Thus, for engines equipped with this style of DPF regeneration, biodiesel blends generally should not exceed B20.
Some DPF systems are able to eliminate this problem by using an extra injector located in the exhaust system to handle regeneration. Such configurations don’t cause engine oil dilution and so are compatible with B100, but they are also less common.
Rule of thumb:
B20 works with DPF-equipped diesel engines. Higher blends work with some engines with specific configurations for DPF regeneration.
Complications associated with using B100 may vary from negligible to major, depending on the engine configuration and the operating environment. B20 and lower blends, on the other hand, present minimal complications when used in any modern diesel engine and in all but the coldest operating environments.
Diesel Generator Rentals
Red-D-Arc carries diesel, LPG and natural gas generators in a range of sizes.
D&D Power provides full service oilfield generator rentals including generator paralleling.
We also provide diesel air compressors for rent.
Red-D-Arc was featured in the December/January issue of Tank Storage Magazine in an editorial titled “Rental welding equipment for storage tank fabricators”. Tank Storage Magazine is an industry leading publication, reporting exclusively on the bulk liquid tank storage and terminal sector.
The storage tank construction industry is highly competitive and fabricators gain a significant advantage by leveraging Red-D-Arc’s rental fleet of automatic tank welding equipment. Red-D-Arc supplies specialized automatic storage tank welding equipment to companies in the tank fabrication industry for projects all over the world.
Along with our specialized tank welding equipment comes a highly knowledgeable and experienced team of Red-D-Arc technicians. Sayer Hendricks – storage tank welding equipment specialist at Red-D-Arc is quoted in the article: “A fabrication company without prior knowledge of the equipment, is able to rent a turn-key tank welding automation system and increase their welding productivity by 40-50%. With on-site training, service and support, our customers are up and running quickly and making 100% x-ray quality welds without fail”
The full article is available here: Rental welding equipment for storage tank fabricators
Scheduled for completion in July 2016, U.S. Bank Stadium, the new home of the Minnesota Vikings, is a fixed roof structure that will be nearly 30 stories tall at its highest point. During construction, the base plates of some of the structural support columns needed to be pre-heated to 400o prior to welding. Traditional heating by flame proved to be difficult. It was determined that induction heating was the right solution to safely and efficiently heat the steel to an exact temperature. Induction heating is the preferred method to address challenges associated with the pre-heating of structural steel because it provides a safe and accurate method of heating the metal to a precise temperature.
Red-D-Arc offers Miller ProHeat 35 Induction Heating Systems (IHS) available for rent, lease and sale. This highly efficient technology uses non-contact heating to induce heat electromagnetically rather than using a heating element in contact with the part.
UPDATE: This project was completed ahead of schedule.