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Induction Heating vs Other Methods

29 April, 19 4:48 am · Leave a comment · Colin Brown
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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.

What is Induction Heating?

Induction heating is a heat treating process that, when used properly, can alter the mechanical properties of a weld and its adjacent base metal in a way that meets the demands of the application in which the weld is being used. Induction heating relies on the science of electromagnetism to heat the part. Induction coils are placed around the material being heat treated, and alternating current is fed through them. This alternating current going through the induction coils creates a rapidly alternating magnetic field.

The eddy currents that occur as a result of this heat the material surrounded by the coils. Magnetic materials are even more easily heated by the alternating magnetic fields.

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Welder shortage: Key is efficiency, not automation

02 April, 19 1:31 pm · Leave a comment · Colin Brown
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Note: This article first appeared in BIC Magazine

In industry, a growing trend is the idea to use orbital welding as a solution to the mounting problem of welder shortages. It is a well-known fact there are just not enough pipeline welders to go around (no pun intended). By 2020, the American Welding Society expects the U.S. will face a shortage of 290,000 welders. Companies in other business sectors — from food service companies to banks — attempt to solve labor issues and increase efficiencies by utilizing automation to replace workers. Is automation, specifically orbital welding in this case, the way to improve operating factors and productivity?

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Axxair Orbital System Makes Welding Small Pipes Easy

18 October, 18 3:12 pm · Leave a comment · reddarc
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multi pipe welded array
Welding small diameter tubing can be difficult.  The tight radii often require expert welders to deliver precise torch manipulation with finesse.  If the welder is not skilled enough, the out of position areas are at risk of poor quality due to gravity affecting the weld pool and ineffective torch angles.  If out of position welds cannot be completed satisfactorily, the part must be rotated.  However, some assemblies can’t be rotated because of size constraints or they might rotate off of center.  If a mechanized welding solution is desired for small diameter components, look no further than our Axxair Orbital Fusion Closed Welding Head Systems.


Closed-Head Pipe Welders

Axxair Orbital Fusion Closed Welding Systems are comprised of two main parts: the
Axxair Orbital Fusion Closed Welding Head
and the Axxair Orbital Inverter Power Supply.  The Orbital Fusion Closed Welding Head fully encompasses the assembly being welded.  This means that an inert gas environment can be created around the part, preventing it from the risk of oxidation that it might be exposed to during a welding operation that relies solely on a gas nozzle.  The Orbital Fusion Closed Welding Head also has a ring drive that enables full 360 degree motion around the weld joint, all the while keeping a consistent torch angle.  Furthermore, it is capable of going over 360 degrees for when slope-in and slope-out parameters are needed.
Closed Welding Heads

“The Orbital Fusion Closed Welding Head also has a ring drive that enables full 360 degree motion around the weld joint, all the while keeping a consistent torch angle.”

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Strengthening Metal Parts with Hardfacing

27 April, 18 2:42 pm · Leave a comment · reddarc
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Metallic parts sometimes fail their intended use at a lower stress than they are designated for.
Various forms of wear such as abrasion, impact, metal to metal contact, heat, and corrosion can compromise the strength of metal pieces. This is where hardfacing comes in. Hardfacing is a technique which can be applied to minimize the damage from these types of wear, helping to prolong the life of metal pieces.

What is hardfacing?

Hardfacing —often called hardsurfacing— is the covering of the metallic part with a wear resistant metal by welding. Alloys which commonly need to be hardfaced include carbon alloy and low alloy steels whose carbon content is lower than 1 %. These include stainless steels, manganese steels, cast iron as well as nickel and copper-based alloys.

Metallic parts sometimes fail their intended use at a lower stress than they are designated for.

Techniques, Materials and Costs

The particular hardfacing technique for a job depends on the geometry of the part and relative cost of the hardfacing method. Costs can vary with the deposition rate of the material.

These cost variations can be summarized as follows:

  • Flux cored arc welding (FCAW) 8 to 25 lb/hr
  • Shielded Metal Arc Welding (SMAW) 3 to 5 lb/hr
  • Gas Metal Arc Welding (GMAW), including both gas-shielded and open arc welding 5 to 12 lb/hr
  • Oxyfuel Welding (OFW) 5 to 10 lb/hr

 

Applied materials commonly include cobalt based alloys such as STELITE, and nickel based materials like chromium carbide alloys. More advanced materials such as complex carbides containing columbium, molybdenum, tungsten, or vanadium can also be used and provide more overall abrasion resistance. They also have a very low friction factor, which can be used in situations involving severe abrasion.

Hardfacing can be applied to both newly manufactured pieces, in order to prevent deterioration, or to strengthen and extend the life of worn pieces currently in use.

Red-D-Arc provides welding machines suitable for hardfacing using techniques including SMAW, FCAW and GMAW.

The Importance of Welding Surface Preparation

28 March, 18 2:08 pm · Leave a comment · reddarc
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By guest blogger David H.

welding surface preparationHaving worked in shipyards for seven years, I’m familiar with how dirty this type of job site can be. Ship repair worksites and welding surfaces are often filthy with rust, dust and other contaminants. Even in shops and yards where fabrication is ongoing, cleanliness is often lacking. If fabricated or refurbished pieces are being installed onboard, the surface to which the piece will be welded could be rusty, coated with scale, or have other types of corrosion.
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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.