Purchasing a new plasma cutter sometime soon? Take advantage of this great deal and be rewarded for your good choices! From October 7th until December 31, 2024* score a FREE consumables kit when you purchase a Powermax30 AIR, Powermax30 XP or Powermax45 XP plasma cutting system!

All welders know that safety is top priority- but with new technology on the market like the handheld laser welder Theo from Maxphotonics, it's important to understand that this new tech calls for a new set of safety needs! So what are the differences between laser welding and traditional welding when it comes to considering safety? Read on to learn more about laser welding safety protocols and how you can create a safe laser welding workspace at your shop! 

Traditional welding techniques require extensive personal protective equipment (PPE) such as helmets, gloves, jackets, long pants, and boots to shield against bright arcs and sparks. And while laser welding doesn't tend to produce a ton of sparks, it is still recommended that you take precautions to cover your extremities. However, the real danger when it comes to handheld laser welders, is actually invisible to the human eye!

What many people don't realize is that the 1.5-kW, 1-µm-wavelength fiber laser coming from your welder is the same class 4 laser that many fabricators use for cutting- the only difference is that the laser on the cutting machine operates within an enclosure, behind laser safe-glass. Just because you cannot see the beam, doesn't mean it won't impact your retina or the retinas of those around you. This invisibility calls for specialized laser-safe eyewear, like laser glasses and welding helmets equipped with laser-safe glass lenses, as well as barriers to protect those who are in the vicinity from exposure. 

Safety in laser welding begins with designing a restricted-access area. Make sure you clearly mark the area, minimizing  unnecessary access and exposure. Appropriate warning signs are crucial at all entry points, clearly indicating that a laser is in use. These signs must comply with safety standards and include information about the type and class of laser, potential hazards, and required PPE. Regulations tend to vary by country and region, so check out your local regulations for guidance. 

Once you figure out your barrier set up, there are still other considerations. Even though laser welding is different to traditional welding, effective fume extraction is still crucial for maintaining air quality since both methods still create harmful fumes. Check out our recommendations for PAPRs and other fume mitigating systems like portable fume extractors, booths, downdraft tables, and more!

Additionally, as discussed above, all welding requires appropriate PPE. This includes your standard gloves, jackets, long pants, and boots, plus laser safety glasses with the proper rating and a welding helmet with a laser safe lens. 
 
Fire safety is also an important requirement for any welding job, including laser welding. Make sure your space is equipped with suitable fire extinguishers and be sure that fire detection and suppression systems are in place! And as always, keep flammable materials away from the area you are welding in to minimize fire risks.

Another way to stay safe is to keep your equipment up to par with regular maintenance and inspections. This ensures that equipment functions correctly. Make regular inspections part of your routine to help identify potential issues before they become significant problems.
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And then lastly, and perhaps most important, proper training and awareness! If your staff doesn't know the dangers or can't physically see them, as is the case with laser beams, then how can they be expected to work safely? Shops must designate Laser Safety Officers (LSOs) who understand laser classifications, hazards, and safety protocols in depth. Training for LSOs can be conducted online or in-person, and it’s crucial that they have a full understanding. All operators of the laser welder should also receive safety training- keep your staff informed by investing in training BEFORE implementing laser welding at your business. Regularly reinforce the importance of following safety protocols with refresher training sessions. 

When it comes to pipe handling in industrial settings, efficiency and safety are top of mind. Using the right equipment can drastically reduce downtime, increase precision, and ensure that your job site operations run smoothly. When it comes to pipe rigging equipment, Mathey Dearman is one of our top recommendations! Today we're talking about our favorite solutions that improve both productivity and safety for pipe handlers.  Let's explore their options- from Beam & Pipe Launchers, to Clamp Rollers and Cradles & Slings. We’ll break down key features of each solution and discuss their benefits and uses so you can make the best decision for the job. 

Mathey Dearman’s Beam & Pipe Launchers are designed for precise and safe pipe handling. These strong, American-made tools are essential for launching, positioning, and supporting large pipes during installation. Their latest line of pipe launchers stands out for its convertible design, allowing them to transition from a heavy-duty pipe launcher to an I-beam and pipe roller seamlessly. This dual-purpose capability makes them indispensable for large pipe welding, alignment jobs, and pipeline work.

Mathey Dearman's Cradles & Slings are designed to safely lift and transport pipes across the job site. Whether you’re working in confined spaces or need to move heavy pipes over long distances, these tools provide the stability and control necessary to prevent damage and ensure smooth handling. Made from high-quality materials, these Cradles & Slings are designed to handle heavy loads without compromising on safety or performance!

Beam Clamp Rollers are another essential tool for anyone involved in pipe welding, fabrication, or handling. These rollers can be used for a variety of industries and applications, but are typically seen in the installation of pipes into racks at refineries, power stations and other industrial plants. They allow for smooth pipe rotation, enabling precise alignment without damaging the surface of the pipe. Clamp Rollers work by securely gripping pipes, then enabling easy rotation, making the welding process more streamlined and accurate.

All the Mathey Dearman Beam Clamp Rollers are designed to be light weight, with I-beam clamps for quick installation and various roller head options so that all sizes and weights of pipe can be easily, safely and efficiently installed!

In the world of welding, sometimes power and performance come at the cost of convenience. Traditional welding systems rely heavily on power sources to keep a stable arc, making off-grid welding a challenge. Which is why we’d like to tell you a little bit about Fronius’ AccuPocket- a groundbreaking battery-powered welder that provides high-performance welding with or WITHOUT access to electricity!

The AccuPocket is portable battery-powered welder that has options for both Stick and TIG welding. Its unique ability to operate independently from a power grid allows welders to perform jobs in remote locations without the need for heavy generators or long cumbersome power leads. This welder offers a versatile welding amperage range of 10-140 A for Stick and from 3-150 A for TIG, making it powerful enough for a wide variety of applications!

The AccuPocket incorporates the latest in battery technology that ensures a long lifespan, no memory effect, and low self-discharge, allowing for extended use in the field without frequent recharging. Built for the toughest environments, it has an integrated dust filter, raised feet to prevent water damage, and sturdy housing that makes it highly durable. It’s also compact and lightweight, weighing only 24.25 lbs without the charger, making it a breeze to transport!

​At the heart of the AccuPocket’s performance is AccuBoost Technology, which enhances arc stability and overall welding quality. This technology uses high short-circuit currents to ensure easy ignition and smooth arc operation, preventing electrode sticking, and ensuring consistent weld quality regardless of battery status. It’s compatible with a wide range of electrodes, including rutile, basic, and CEL electrodes, allowing for greater versatility in welding projects. Whether working on a construction site or performing delicate TIG welding, this tool provides the same level of performance as a traditional mains-powered welder.

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Welding is an essential process in many industries, but like many other things, it is not without risks. It's is important for both welders and their employers to properly mitigate them. Today, the risk we’re specifically talking about is the fumes generated during the welding process. Welding fumes are a complex mixture of airborne particles and gases created when metals are heated above their boiling point. This results in vaporization that then condenses into fine particles and can contain a variety of hazardous substances- including manganese, hexavalent chromium, nickel, and zinc!

The Occupational Safety and Health Administration (OSHA) has established strict regulations regarding permissible exposure limits (PELs) for various welding fumes, as well as a hierarchy of controls that can be used to protect workers. Staying compliant with these regulations requires more than just awareness—it demands action. So today we're talking about engineering controls that welders and their employers can make use of to stay safe. 

Fume extractors are a critical component of engineering controls. They work by capturing welding fumes at the source, filtering out harmful particles, and returning clean air to the workspace. By effectively reducing airborne contaminants, fume extractors help to protect workers from the health risks associated with welding.

Are you looking to upgrade your welding equipment and save money in the process? Now is the perfect time with Lincoln Electric's "Buy Red, Save Green" promotion! For a limited time, you can receive incredible rebates on a wide range of high-quality Lincoln Electric welding and cutting products.

Whether you're a professional welder or a hobbyist, this deal offers significant savings on top-of-the-line equipment. Don't miss out on this opportunity to up your welding game while keeping more green in your pocket. Explore the featured products below and take advantage of these rebates today!

Here at Earlbeck we are always looking for ways that our students can get a helping hand with the financial costs associated with welder training. This is why we’re excited to tell you about CCBC’s No-Cost Workforce Training Program!

If you’re ready to start down the path to an exciting career in welding but not sure if you can afford the initial costs- CCBC is here to help with that! Their mission to empower students by providing comprehensive, high-demand skills training at no cost! They provide Baltimore County residents that are seeking training in Welding, Maintenance, HVAC and IT with free tuition and peace of mind- allowing them to learn and succeed, worry-free!

Since our Technical Center partners with CCBC to provide their comprehensive welding courses, our program is a part of this initiative- offering you the opportunity to gain critical knowledge and skills in a rapidly growing field!

​Check out the information below to see if you qualify and to learn how to apply today!

The next available round of tuition funding for CCBC's Welding Program is for the Spring 2025 semester. To be considered, be sure to complete the intake form by the March 14, 2025 deadline! 

Don't let this opportunity pass you by! Apply today by clicking the banner below! 

For more information on CCBC's free tuition programs, click here. For specific questions about this program, please contact [email protected] or [email protected].

The Maryland Department of Commerce’s Manufacturing 4.0 Grant applications open August 1st, 2024! If you are a small to mid-sized manufacturing company that was planning on integrating advanced technologies into your workflow, then this grant was made for you!

The Maryland 4.0 Manufacturing Grant program is designed to inject fresh energy into local manufacturing businesses by financially supporting the adoption of cutting-edge technologies. It's all about bringing the future of manufacturing into today's factories, making them smarter and more efficient!

Maryland is offering to cover up to half of your project costs, with grants ranging from $25,000 all the way up to $500,000. Whether it's robotics, digital enhancements, or new software that connects and streamlines your operations, this grant is here to help you afford these big leaps forward!

This grant is aimed at projects that demonstrate a clear tie to Industry 4.0 technologies- so think sensors and AI that will improve your manufacturing process, track preventative maintenance, productivity levels, machine uptime/downtime and more! Let's explore some key ways metal fabricators can harness this grant program to optimize their operations:

When applying, it's important to show how the technology you want to implement will transform your business operations and set you up for future successes. Projects must be new or significantly enhance existing capabilities and should not have begun before the grant application period. If you're upgrading with innovative tech like standalone software systems that aren't tied to existing hardware, these are eligible under the grant!

To be eligible for the Maryland 4.0 Manufacturing Grant, your business should already be operational and in good standing with the State of Maryland. It's necessary to employ between 3 and 250 full-time workers, defined as individuals who work at least 1,800 hours over a 12-month period. Your business should fall under the NAICS two-digit codes of 31, 32, or 33, indicating a manufacturing focus, and it must have been established for at least two years. Additionally, compliance with both federal and Maryland-specific Occupational Safety and Health Administration regulations is required. Applicants must show not only the capability to implement the proposed project successfully but also a strong commitment or strategic approach to adopting Industry 4.0 technologies. Lastly, the ability to provide matching funds is crucial to demonstrate financial readiness for the anticipated technological upgrades!

In the world of welding, efficiency and quality are paramount. There are plenty of variables you'll encounter in your pursuit of the best results while welding, but today we are talking about welding wire- specifically metal-cored wire. Using metal-cored wire in the appropriate applications can reduce costs, enhance quality, and boost productivity in welding operations. Understanding the optimal times and methods for utilizing this wire can help companies maximize its benefits. So let’s breakdown what metal cored wire actually is and what the benefits and considerations are.

Metal-cored wire is a type of welding consumable that combines the benefits of solid wire and flux-cored wire. It’s classified under AWS A5.18 as a mild steel GMAW or MIG wire, but it differs from solid wire in its structure. This is because it is a composite, tubular wire filled with materials such as iron powder, arc stabilizers, and other additional alloys that help with specific mechanical properties. The composition of materials within metal-cored wire can differ based on the specific properties and characteristics required of the filler metal.

​Unlike solid wire, the core of metal-cored wire does not conduct electricity; the current travels only through the outer metal sheath. This unique construction allows metal-cored wire to maintain a higher current density at the same amperage, leading to increased productivity, excellent penetration, and a more appealing operation in axial or pulsed spray transfer modes. Due to these characteristics, metal-cored wire is not suitable for use in short circuit transfer.

To achieve optimal results with metal-cored wire, the right shielding gas mix—typically a blend of argon and carbon dioxide—is essential. Welders must also ensure that their equipment is compatible with metal-cored wire, which may involve adjustments to voltage settings and feed speed to accommodate the wire’s unique properties.  And as always, price must also be considered- when compared to solid wire, metal cored wire tends to be about 15% higher in price. However, with the right application, this 15% increase is made up by metal cored wire offering more efficiency and less re-working and finishing, which means less labor costs!

Metal cored wire is not recommended for every application, for instance it does not excel in short circuit transfer. It is also not great for sheet metal application. But industries like automotive manufacturing to heavy machinery construction, where production efficiency and weld quality are crucial, choose metal-cored wire. It is also particularly effective in robotic welding and automated applications, where its consistent feeding properties and high deposition rates can be fully utilized to up your productivity.

While metal-cored wire offers numerous benefits, the cost can be higher than that of solid wire. However, the overall savings in labor, cleanup, and increased productivity often offset the initial investment. This is a material that offers significant advantages in both efficiency and quality! Its ability to improve productivity and reduce operational costs makes it a valuable option for many industrial applications.

As the landscape of manufacturing continues to evolve, we are discovering that advanced technologies like collaborative robots are no longer just the domain of large industrial outfits. With the advent of more accessible, flexible, and cost-effective solutions, even small-scale operations can harness the power of robotics to enhance their productivity and quality!

Collaborative robots, or cobots, are designed to work alongside humans in a shared workspace without the need for traditional safety barriers. This actually makes them ideal for smaller shops where space and versatility are at a premium. 

As with implementing anything new in your shop or business, there are always things to consider before taking the plunge. Since we are in the welding business, this article will mostly focus on cobot welding, but many of these considerations can be applied to other robotic tasks. So let’s talk about the benefits, considerations, and challenges- and how to navigate them! 

BENEFITS: Robotic systems bring a level of precision and reliability that boosts both productivity and the quality of the final product. This high quality reduces the need for rework and associated costs, directly saving time and money. Additionally, these systems cut down on waste and reduce labor needs- thanks to precise control over the welding metal, each pass uses the correct amount of material, which avoids overwelding and requires less supervision 

For larger operations with deeper pockets, the benefits of automation are clear, but smaller outfits also stand to gain significantly. They can achieve greater operational flexibility and leverage automation to foster a collaborative work environment. This often leads to increased staff engagement and innovation. By automating repetitive tasks, these systems free up skilled workers to focus on more complex tasks, adding value to the manufacturing process.

CONSIDERATIONS: When thinking about integrating robotic welding, shops should start by assessing their specific pain points. What problem are you hoping to improve or solve with automation? Whether it's ramping up production speed, enhancing the quality of welds, or streamlining operator training, identifying these goals early can help you get the most out of your cobot. 

The initial investment in this tech can be substantial, but the long-term savings are even greater. By increasing efficiency and reducing waste, these systems pay for themselves over time. Shops can achieve a lower total cost of ownership due to decreased needs for repairs and downtime. ​

CHALLENGES: Integrating robotic technology into a small shop can come with challenges- think workflow changes, part design, space constraints, and training hurdles- so let's talk about what you can do to make sure your implementation is successful. 

We're always keeping our eyes peeled for opportunities that can help the next generation of students advance. Scoring scholarship funds is a great way to get on the path towards a career in welding and manufacturing without breaking the bank! So unlock your future with this exciting opportunity from Nuts, Bolts & Thingamajigs!

NBT, the charitable foundation of the Fabricators and Manufacturers Association, has been lending a helping hand to the next generation of manufacturing professionals since 1990! They offer scholarships twice a year to students dedicated to building careers the manufacturing field. So if your program is geared towards manufacturing, no matter if you're attending trade school, community/technical college, or university, this scholarship could be for you!

There are three awards opportunities under just one application- and if chosen, students will receive up to $2,000 per semester! This award may be used to defray the cost of tuition, books, and school fees. Required educational equipment or tools may also be covered in some circumstances.

​The NBT Scholarship not only provides financial assistance but also opens doors to networking opportunities, professional development, and a pathway to a rewarding career in manufacturing. For prospective students at Earlbeck Technical Center, this scholarship can significantly offset educational expenses and help you get ahead! It’s an excellent opportunity to gain financial support while working towards your career goals!

Summer is here and we are thrilled to announce two new Fronius deals! Whether you're focused  on upping your game for TIG or MIG welding, these offers are an easy way to improve your welding experience with top-of-the-line Fronius products. Don't miss out on these fantastic deals, valid for a limited time only!

These summer deals are perfect for both new and experienced welders looking to upgrade their equipment with Fronius' high-quality products. Don't miss out on these limited-time offers!

For more details, visit one of our showrooms in MD or PA, or reach out today! Let’s make this summer a season of growth and productivity in your welding journey!

June is National Safety Month, an important time to reflect on and reinforce safety practices! Since welding involves inherent risks like exposure to intense UV radiation, infrared light, and flying debris, safety concerns are a top priority in our industry. Fire hazards and health risks from weld fumes add to the complexity of maintaining a safe work environment.  

So let's talk safety- regular training and adherence to protocols are important for preventing accidents and promoting a culture of safety in the workplace. Today we're covering essential personal protective equipment (PPE), proper ventilation, proactive safety measures like the development of a comprehensive shop safety plan, proper cylinder handling, and more! ​

In the world of industrial welding, efficiency and reliability in wire delivery systems is crucial! Wire spools are typically available in a variety of sizes, but if you’re in the business of something like automotive manufacturing or shipbuilding, where smaller spools would be finished in a second, you may have already swapped to a bulk wire drum system. 

And if you have, then you know that while traditional wire drum systems offer more wire and less downtime replacing spools, they also come with their own frustrating and time-consuming issue: wire tangling. This not only slows down the workflow but also impacts the overall productivity and leads to increased labor costs as workers must spend time untangling or replacing wire.

Thankfully Lincoln Electric has developed a surprisingly simple, yet innovative, solution to address this common challenge: Gem-Pak!

So what exactly is Lincoln Electric's Gem-Pak and how does it work? It's a bulk wire delivery system that incorporates an ingenious use of glass gems! The irritatingly common tangling issue you see with softer, more pliable materials like aluminum, is easily solved by filling the drum with small glass marble-like gems. This prevents the aluminum wire within the drum from moving around, and that lack of movement means no dreaded tangles!

Lincoln Electric boasts a "Tangle-Free Guarantee" when using the Gem-Pak, underscoring their confidence in this innovative solution. The patented design helps to minimize arc-flaring as well as tip burnback, saving you time and money! Plus, it's designed to integrate seamlessly into existing setups, requiring no additional complex external pay-off systems, making it a good option for any company looking to enhance their welding efficiency.

In the world of metal fabrication, controlling costs while maintaining quality is always at the top of mind. As industries strive for efficiency, incorporating lean manufacturing principles into your welding operations presents both a promising solution and an interesting question: How do you accomplish lean welding? 

Due to the amount of variables involved in welding (think material irregularities, fit-up variations,  cleanliness of parts, etc.) it can be difficult to quantify the amount of time actually needed to produce a weldment from start to finish. These variations can drastically affect productivity and quality, and the unpredictability is costly. Excessive use of materials and extended labor hours can also make it difficult to include welding in a production system that depends on the flow of components staying consistent, as they do in a lean manufacturing environment. 

So let's explore what you can control in the process, remove bottlenecks, and how to best incorporate lean manufacturing  practices to reduce waste and lower operational costs! 

​Lean manufacturing aims to maximize value by minimizing waste, so now how do you begin to apply these principles to welding to not only reduce waste but also significantly lower operational costs?

For starters, controlling the factors that both precede and follow welding operations can really help save on labor costs. Processes such as material prep and post-weld treatments can be standardized so that the components that enter the welding cell meet precise specifications, consistently. This reduces the variability in welding operations, leading to faster production times and more consistent results.  

On top of that, strategic process changes can reduce the time needed for each welding job. Your active welding time can be increased through things such as automation, better fixturing, moving to low or no spatter/slag processes, and even implementing procedures that help reduce rework.  Another saver on labor costs is considering deposition rate and travel speed. Maximizing these should reduce the time it takes to weld a particular assembly, cutting labor costs while maintaining or even improving quality!

Combating overwelding, however,  requires a proactive approach, starting with strict adherence to welding specifications and design plans. Additionally, investing in training for welders to understand the importance of precision can help reduce the inclination to overweld. Adopting high-efficiency consumables and optimizing the your welding process through advanced techniques can also increase deposition rates and travel speeds, further decreasing the need for excessive welding and reducing both material use and labor time.

Lincoln Electric is a known stand out in the welding industry, for their quality, durability, and innovation. They offer tons of solutions that enhance productivity and results, but one you may not have heard of yet is HyperFill!

HyperFill is an advanced welding solution that uses twin-wire technology to achieve greater control, higher deposition rates, and increased weld quality compared to traditional single-wire MIG welding. Unlike conventional methods, HyperFill allows for a higher deposition area while still remaining stable, which means faster welding with fewer passes. This technology is compatible with a variety of Lincoln Electric's existing power sources, making it an easily integratable solution for various applications.

It’s just one power source, one wire feeder, one tip, but twin wire: achieving amazing deposition rates with a wide, smooth arc cone and no added complexity!

HyperFill offers quite the list of benefits that make it a standout choice for improving welding efficiency and quality. It delivers better penetration and a more controllable arc, which leads to cleaner work with less spatter and cleanup. And not only does it produce significantly lower fume emissions per pound of deposit, but it also requires less heat input. This reduction in heat contributes to fewer passes needed during welding, resulting in less distortion of the materials and better mechanical properties overall. At the end of the day, it is hard to pass up on HyperFill's impressive increase in deposition rates, from 12 to 20 lbs. per hour, making it a highly efficient solution for various welding needs!