When it comes to welding, choosing the right method can have a significant impact on quality, efficiency, and overall production time. Traditional welding processes, like MIG and TIG, have long been the go-to choices for many industries, but lately laser welding has been a hot topic of conversation in the industry. Wondering if laser welding will replace TIG? 

While traditional processes have their place, we firmly believe that laser welding is  revolutionizing modern fabrication! Read on for a breakdown of the differences between these methods, from training to final results, and you’ll see how laser welding stands out from the crowd!

As a welding technical school, we know better than anyone that learning how to weld, and weld well, takes time and effort. When it comes to TIG welding, while useful for a variety of jobs, it demands a pretty high level of skill and significant training time to master. TIG welders need precise hand coordination to juggle the torch, filler material, and pedal controls simultaneously. Additionally the set up requires adjustments to the gas flow, electrode type, and torch angles. Even minor missteps can lead to weld defects or inconsistent results, adding more time to the process. This learning curve can delay the onboarding of new welders and significantly increase training costs.

Weld quality is another area where laser welding really stands out. TIG welding, while capable of producing high-quality welds, often struggles with issues like spatter, contamination, and uneven penetration—particularly when operated by welders with less experience. TIG welding’s reliance on the manual control of the welder means more room for human error, often leading to welds that need rework. Grinding and cleaning are common post-weld tasks that consume time and labor, driving up costs and extending the production timeline.
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MIG welding, while faster than TIG, often produces welds with more spatter and less precision, especially on thinner materials. This can lead to defects and the need for additional cleaning or rework- and those post weld tasks can add up!

Laser welding, on the other hand, produces exceptionally clean, precise welds with minimal spatter and distortion. Laser allows for consistent penetration and fusion, making the likelihood of defects significantly less. The results of laser welding often require no additional cleaning or finishing, and this reduction in rework not only saves time but also increases overall productivity, allowing teams to focus on new projects instead of reworking and fixing old ones.

Clarity ratings provide a standardized measure of how well a welding helmet lens performs under specific conditions. You may have come across different ways of expressing these clarity ratings so let's discuss the differences. Put simply, ANSI Z87.1 standards provide guidelines specific to eye and face protection for American industries, while EN379 standards offer a more detailed breakdown of clarity ratings for auto-darkening filters.

ANSI Z87.1
Here in the U.S., the American National Standards Institute (ANSI) offers clarity rating guidelines under ANSI Z87.1. This standard is what OSHA goes by and it addresses the safety of the lens even if it is not functioning correctly or it's turned off- basically ensuring that the lens passively protects your eyes and face, no matter what. The second thing that the ANZ87.1 standard also regulates is just how much visibility you will get at each shade setting- which is measured by a light transmittance test. This standardized test measures how well you can see the welding arc through the helmet from 0-100% (0% = no visibility and 100% = naked eye). For each lens shade, there is a minimum percent of visible light allowed for top clarity, as well as a maximum percent of light that's allowed, to protect your eyes and reduce fatigue.

EN379
For certain helmets, you may also see an additional rating that is expressed like this: 1/1/1/1. This rating follows the European Standards (EN) clarity rating for Auto-Darkening Helmets. Although these are not mandatory in the U.S., they can be helpful since they do offer a simple breakdown for easy decision making. How it works is that each number corresponds to a graded scaled for four different considerations. Each category is graded from 3 (lowest) to 1 (highest), meaning the highest clarity helmet would be rated as 1/1/1/1 across all categories. These considerations are as follows:

1. Optical Distortion – How clearly you can see through the lens with no warping or bending of the image.
2. Lens Uniformity – The consistency in the quality and purity of the lens material.
3. Dark State Consistency – How consistently dark the lens is.
4. Angle Dependence – The lens’s clarity and darkening performance when looking at an arc from a sharp angle.

Helmets rated by both standards help to provide an extra level of assurance. The ANSI standard ensures safety compliance, while the EN standard measures performance specifically for optical clarity. When comparing helmets, look for lenses that meet the ANSI standard and have the lowest numbers in each category for the EN standard. 

​It seems obvious that using a helmet with excellent optical clarity will help you to produce better welds, simply because you'll be able to see what you're doing. But there are other things at play here- like your comfort and safety- that contribute to the overall experience. Poor clarity can lead to distorted vision which strains your eyes and can affect the precision of your work as well as your productivity. Distortion, in particular, can make it hard to see fine details, which are critical in tasks calling for high accuracy. Helmets with high ratings allow for better visibility in both light and dark states, which gives you better control over your weld and minimizes the potential of mistakes and subsequent rework.

Here are a few practical tips:

1. Check the Light Transmittance Levels – Choose a helmet that meets ANSI Z87.1 standards for light transmittance in both light and dark states. This ensures that the lens provides a clear view without letting harmful levels of light through.
2. Optimize Your Lighting Environment – Even the best clarity-rated helmets can benefit from adequate ambient lighting. If your workspace is dim, consider integrating additional lighting solutions to enhance visibility, either as part of the helmet or through external lighting setups.
3. Invest in High-Quality Lens Accessories – For those who use magnifying lenses, choose ANSI-certified lenses and quality cover lenses to improve clarity and prolong lens life. These accessories can make a big difference in both clarity and comfort.
4. Consider the EN Standard Ratings – If you’re comparing helmets, you'll likely come across the EN optical ratings. While not required in the U.S., these ratings can offer additional insight. Generally you'll want to look at first three categories (1/1/1/x) as they're crucial for welding, while the fourth rating tends to be less impactful because the difference is hard to notice and only applies at extreme viewing angles.

So whether you’re a professional welder or a weekend hobbyist, finding a helmet with superior clarity ratings will pay off in both the short and long term. If you're in the market for a new helmet, keeping these clarity ratings in mind will help you find the perfect balance of comfort, performance, and safety. But if you're not feeling like doing the research, don't worry, we've got you. Check out the short list below to see helmets that we firmly believe are winners when it comes to clarity and comfort!

In today’s competitive manufacturing landscape, fabricators face the constant challenging balance of improving production efficiency while still keeping quality standards high. A great way to overcome this challenge is by leaning into automation. So whether your shop is just dipping a toe into the world of automation, or looking to expand on what you've already got going on, we're here to help you make the right choice for your business needs!

Lincoln Electric offers a suite of automation solutions that are designed to help shops of all sizes-  from the Pantheon customizable column and boom systems to versatile tractors and gantries, these systems optimize welding processes and reduce operational costs. So read on for a breakdown of the benefits and key features of each solution, and see which one works best for you!

Lincoln Electric's Pantheon column and boom systems provide strong, adaptable solutions for high-precision welding in a variety of applications. Whether you are looking for a standard solution to automate repetitive welds or a customized heavy-duty system to handle oversized projects, there's an option that provides the power, precision, and flexibility you need. By automating welds in complex assemblies, your shop can expect higher production rates and greater accuracy, even on large projects. 
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Plus, with Lincoln Electric and Earlbeck's comprehensive technical support and guidance for the Pantheon series, which includes custom upgrades and troubleshooting assistance, shops can tailor their system to meet their current needs and explore scalable options as their operations grow.

Side beams and lathes are an ideal and lower cost pipe welding solution for applications requiring rigid positioning and repeatable results- think roller overlay, shaft rebuilding, or pressure tank assembly. Their compact design ensures efficient use of shop floor space, and they are adaptable to single or multi-head configurations for varied production requirements!

With SAW, MIG, FCAW, and TIG capabilities, a high payload capacity carriage, and a machined rack and pinion system to avoid slippage, you'll maximize your welding accuracy AND consistency in one go! They offer a variety of different control settings, including accurate travel speed and direction control, which allows you complete control of the system. 

Seamers are purpose-built for high-quality, repeatable seam welding- delivering uniform results that are difficult to achieve with manual welding! They let you produce faster and more consistent seam welds, ensuring precise alignment, reducing downtime, and enhancing throughput when it comes to those repetitive welding tasks.

With water-cooled mandrels and clamping fingers, seamers minimize distortion, so you’ll see higher welding speeds without compromising on quality. With SAW MIG and FCAW capability and accommodating outer diameters from 24 to 216 inches and inner diameters from 120 to 240 inches, they’re suitable for a broad range of applications, making them a great investment!

Gantries provide excellent control over long and complex welds, reducing rework and ensuring consistent results. Designed for heavy-duty tasks, Lincoln Electric’s gantries feature robust frames and dual synchronized motors- these systems handle large components and demanding applications with ease!

Capable of welding long lengths consistently with two heads, these gantries can also have the ability to weld butt and fillet joints! Compatible with SMAW or GMAW, Single, Tandem, or Tiny Twin SubArc, MIG, and Hyperfill welding processes- their durability and precision positioning help streamline operations, making them invaluable for jobs that call for high-volume, high-quality welding. Custom solutions are also available if you're looking for more complex beam welding applications or large girders with complex geometry. 

Lincoln Electric’s welding tractors, such as the Weldy Car 2.0 Pro and the Cruiser SAW Tractor, offer portable automation for various welding operations! If you need welding automation on-site or for larger, complex welding environments that call for flexibility, these are the perfect solution.
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Weldy Car 2.0 Pro is a compact, battery powered option for MIG/MAG welding, while the Cruiser, paired with the Power Wave AC/DC 1000, offers modular capabilities for butt and fillet joints. The Cruiser's modularity in particular makes it easy to adapt and scale, with self-propelled carriages that maintain high weld quality even on lengthy welds.
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If you’re looking for the ability to execute long, uninterrupted welds, Lincoln’s tractor options reduce setup times and ensure uniformity, increasing efficiency in complex projects!

As we approach the end of another successful year, it's time to take advantage of this incredible offer from Fronius that will not only enhance your welding capabilities but also ensure you’re equipped with the best of the best!

If you're in the construction industry, infrastructure repair, or any welding job that requires true mobility, then you may have heard of Fronius' Accupocket 150. This small machine is a real powerhouse and a game-changer— it's a revolutionary portable battery powered welding machine known for its versatility and performance! And from right now, November 4th, 2024, through December 31st, 2024 , if you purchase a new Fronius Accupocket 150 you'll score a FREE Fazor 1000 Plus Helmet!

At Earlbeck Gases & Technologies, we know that quality welding comes from practice and skill- and while you can’t buy experience, you can invest in quality tools that make the job smoother. For over 100 years, we've helped welders—both professionals and students—achieve excellence by providing them with the best equipment in the industry. As a leading welding supply company and welding school, we believe in setting our students and customers up for success from the very beginning!

So whether you’re just starting your career or just looking to refresh your kit, here are our recommendations on the basics! This list features brands and tools we trust so you can make informed decisions!