Anyone working in the manufacturing industry knows there’s a lot that goes into staying safe on the job. Whether you’re an employer or employee, you know that health and safety is paramount. Today we're talking about Chromium (VI). Chromium metal is often added to alloy steel to increase hardenability and corrosion resistance, but it is also a known carcinogen. So, if you’re doing stainless steel welding, this is something you need to watch out for. A major source of worker exposure occurs during "hot work" like welding, so it’s very important to determine how much you and your staff is being exposed to.  While we don’t provide hexavalent chromium exposure testing, we're happy to help keep you informed about OSHA guidelines and provide referrals for help with testing to keep you and your team safe and healthy!

It is the employer's responsibility to test to see how much Chromium (VI) they are generating. OSHA has established guidelines to ensure the safety of workers in environments where Chromium (VI) may be present, so let’s review those!

So what happens if you do your testing and find out your employee exposure is at or above the accepted levels? OSHA will require you to perform periodic monitoring and notify your affected employees.

To reduce exposure to hexavalent chromium, the first step is to consider if a process change can be made. The type of welding process, base material, and location should all be considered. Air quality engineers typically recommend starting with a change in welding wire. By switching from flux-core wire to solid wire, weld fumes and exposure to hex chrome can be drastically reduced.

In addition to process improvements, engineering controls play a crucial role in protecting welders from hex chrome. Implementing dust collection systems, such as backdraft tables and fume guns, can efficiently capture weld fumes. 

Furthermore, considering an ambient dust collection system or fume extractor can help mitigate fumes throughout the facility and further reduce exposure to safe levels.  Keep fume hoods, fume extractor guns and vacuum nozzles close to the plume source to remove the maximum amount of fume and gases. Portable or flexible exhaust systems can be positioned so that fume and gases are drawn away from the welder. 

If exposure levels are still too high, the use of personal protective equipment (PPE) should be considered. Powered air-purifying respirators (PAPR's) are a reliable choice for welders in various welding situations. However, it's important to remember that PPE should only be used as a last resort, and engineering controls should always be implemented whenever feasible, according to OSHA guidelines.

By following these steps and prioritizing the well-being of welders, it is possible to significantly reduce exposure to hex chrome and create a safer working environment.

Monitoring Frequency: 
Action Level Exposures: Periodic monitoring, at least every six months.
Permissible Exposure Level Exposures: Periodic monitoring, at least every three months.

Notification Requirement:
You must notify your affected employees within 15 work days of exposure determination. Employers must notify them individually in writing or post the results in a visible location that’s accessible to all affected employees.

Discover the ultimate welding solution that leaves no room for disappointment – the Fronius iWave Multi-Process package. Unlike most multi-process machines that compromise on certain processes, Fronius has seamlessly integrated their top-tier MIG welding machine, the TPSi, with the high-performing iWave TIG machine. This powerhouse combination offers unparalleled flexibility and capability with MIG and TIG features. Get the benefits of a single system that covers every welding process, from TIG and MIG to Stick, while also future-proofing your operations for Industry 4.0! It's time to configure your ideal setup and elevate your welding capabilities to new heights!

Unlock the full spectrum of welding possibilities by seamlessly combining the iWave 300i, 400i, or 500i with the Multiprocess PRO option. Whether your project demands TIG, MIG, or Stick solutions, this innovative approach offers the freedom to unleash your welding potential.

You even have the option of professional manual metal arc welding, complete with all the advantages of cellulose electrode welding. 

​What sets this apart from conventional multiprocess systems is the inclusion of not only advanced TIG functions but also access to every process variant within the realm of MIG welding. Think CMT, PMC, and LSC! Easily tailor your welding experience precisely to your requirements with Fronius's amazing modular welding packages. Let's learn more about what the iWave can do!

CMT (Cold Metal Transfer) process sets itself apart from traditional MIG/MAG welding with its remarkably low heat input and consistently stable arc. CMT lets users join diverse materials, such as steel and aluminum, with ease! The advanced digital process control regulates and maintains a  low current and ensuring spatter-free material transfer. The arc length is detected and adjusted mechanically so it remains stable, no matter the workpiece surface or how fast you weld. This versatility allows CMT to be used anywhere and everywhere, and in every position!

CMT welding is great for joining steel and aluminium and it also produces virtually spatter-free brazing of hot-galvanised and electrolytically galvanised sheets with a welding wire made from a copper-silicon alloy. Experience minimal distortion of the galvanised sheet and light-gauge welding of aluminium sheets- the low heat input eliminates the need for pool support. You can also achieve impressive results when welding stainless steels and magnesium.

PMC (Pulse Multi Control) process ​elevates the pulsed arc and its stabilizers to new levels. This refined process is distinguished by meticulously controlled, low-spatter droplet detachment. PMC also produces a robust and steady arc, providing impeccable control over the weld pool. Avoid imperfections and ensure consistently reproducible and stable results! Optimized welding for vertical-up seams allows for TIG-like seam rippling, at 40% faster speed, all without the need for an oscillating motion. Plus, PMC considerably reduces the consumption of wearing parts and components, saving you money on your bottom line. 

PMC is ideal for narrow welds with a small opening angle or jobs that require high speeds and high penetration. See improved results particularly for small gaps, fillet welds, and root passes!

LSC (Low Spatter Control) process is a modified dip transfer arc with extremely high arc stability. Achieve top-notch weld seams with minimal spattering and an enhanced deposition rate, even in an intermediate and spray arc. The foundation of the LSC process lies in the short circuit occurring at a low current level, leading to a gentle re-ignition and a stable welding process. The remarkable performance of the TPS/i plays a crucial role, swiftly recognizing the process phases during the short circuit and responding accordingly. You can achieve outstanding results in conjunction with the penetration stabilizer, especially in a spray arc.

LSC offers big advantages for manual applications- see high weld seam quality with up to 75% less spatter! It’s also idea for root pass welding without weld-pool support, or welding in the downward position or overhead position. Less reworking, less cleaning, less filler material consumption, and less reject welds means less stress and less money wasted!

First, place your order for the OPT/i Multiprocess PRO hardware option. Second, expand your modular welding system by integrating essential MIG hardware components, including an external wire feeder, welding torches, and more. Finally, customize your welding experience by selecting the MIG Welding Packages that best suit your needs! With this seamless process, you'll be equipped to tackle a wide range of welding challenges with precision and efficiency.

The Fronius iWave Multi-Process package is the ultimate welding solution, ensuring a comprehensive welding experience. With seamless process switching, space-efficient design, and compatibility with all Fronius welding process variants, the Multiprocess PRO stands as a testament to innovation in welding technology!

Head into the new year with a new machine and be rewarded for it with a free MIG torch and consumable package! For a limited time, Fronius is offering a free additional MIG torch and .045 AL consumable bundle with purchase of the TransSteel 2200 or 2700. These robust machines are your ticket to getting the job done seamlessly, and the best part? You get to level up without breaking the bank!

This fantastic deal is only available for a short time from 11/24/23 to 12/31/23, so don’t delay! Don't miss out on the chance to grab these holiday savings and upgrade your welding game with Fronius. If you’ve been eyeing a TransSteel but don’t know which one is right for you, dive into the details with the rundown below. Let's uncover how you can make the most of this limited-time offer, enhance your welding capabilities, and boost efficiency with Fronius! 

The TransSteel 2200 is the ultimate 3-in-1 welding solution that revolutionizes the welding experience for professionals. This compact powerhouse from Fronius, designed to master MIG, TIG, and Stick with unparalleled efficiency. Whether you're on a construction site, in a workshop, or tackling tasks in agricultural or metalworking sectors, the TransSteel Multiprocess series is your go-to companion for assembly, repair, and maintenance work!
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Weighing in at a mere 34lbs the TransSteel 2200 is not only robust and reliable but also one of the lightest devices on the market. It's a single-phase inverter power source, marking a milestone for Fronius as the first of its kind that seamlessly combines MIG, TIG, and  capabilities in one sleek device. There's no need for separate power sources, and there’s no compromise on quality for any of the processes as it effortlessly handles various welding applications!

What sets the TransSteel 2200 apart is its user-friendly design, allowing you to start working immediately! The front panel provides easy access to all essential welding parameters- choose your gas, wire diameter, and material thickness and then begin welding. Set up to two presets with the EasyJobs function, allowing you to replicate your successes. 

Just like the 2200, the TransSteel 2700 is an amazing 3-in-1 welding solution designed to master MIG, TIG, and Stick with unparalleled efficiency. Your dedicated partner while working on a construction site or in a workshop, or tackling assembly, repair, and maintenance tasks in a variety of sectors!

A little heavier in weight and output power than the 2200, there's still no need for separate power sources, and no compromise on quality for any of the processes! Like all Multiprocess welding systems from Fronius, the TransSteel 2700 is ready for use immediately. Pick your parameters on the easy to use front panel and get to welding. Utilize the EasyJobs function to create and store up to five presets, streamlining the process of replicating your successful configurations. You can switch between the individual welding processes in 60 seconds. It also features a side window and LED internal illumination for easy spool checking! The TransSteel 2700 can be used as a single-phase device up to 220A (TIG).

Here at Earlbeck we understand that when you invest in a welding machine, it's not just about the purchase; it's about the long-term value and the work you are able to produce with it. We've been in the welding business for over a century, and during that time, we've learned a thing or two about how to get the most out of your hard-earned money.

We’d love to share some valuable insights that can make real difference in your workflow. Today we are focusing on the Bobcat 225, a Miller brand engine-driven welding machine that we see regularly in our service shop due to it's popularity. You can use the Bobcat 225 for Stick, MIG, and non-critical TIG welding as well as to power tools as a generator. So let’s make sure you get the most out of those capabilities addressing costly and potentially dangerous mistakes!

Make the most of your machine by  focusing on maintenance. It all starts with a small but incredibly important item that often gets overlooked: the manual that comes with your welding machine.
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You might be thinking, "What's the big deal about a manual?" Well, it's a big deal. Your welding machine's manual is a treasure trove of knowledge and guidance that can make a world of difference. It's your key to understanding your machine inside and out, even before you unpack it. Additionally, it plays a crucial role in setting up and maintaining your machine properly- so let's discuss routine maintenance!

Every 8 hours you should be checking your fuel level. Always leave filler neck empty to allow room for expansion. Check fuel level on a cold engine before use each day. Another important check is your oil level.  Check oil with the unit on level surface and if the oil is not up to full mark on dipstick, add some more. Be sure to clean up any spilled oil or fuel before using your machine.

Every 25 hours be sure to clean your air cleaner wrapper. Never run your engine without air cleaner or with dirty element. Wash precleaner with soap and water solution. Allow precleaner to air dry completely. Then spread 1 tablespoon SAE 30 oil evenly into precleaner and squeeze out any excess oil. Simply replace the element if damaged, dirty, or oily. 

Every 50 hours make sure you check on your weld terminals. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. You can use any clean hand brush to remove debris.

Every 100 hours take a look at your battery terminals and clean them with a clean hand brush. If there is battery discharge, clean the battery, terminals, and posts with baking soda and water solution and then rinse with clear water.  You'll also want to clean your cooling system with a clean brush to keep it running smoothly. Additionally you'll want to change your oil at 100 hours. First stop your engine and let it cool- then drain the oil, close the valve and valve cap, and fill the crankcase with new oil to full mark on dipstick. Wipe up any spilled fuel, start engine, and check for fuel leaks. And lastly you'll want to check if you need to replace your air cleaner wrapper.

Every 200 hours you'll want to check your machine's labels and replace any that have become unreadable from being on the job. Next you'll want to check the spark plug gap. Severely worn spark plugs will not ignite the air and fuel mixture. Engine will start hard and run very rough. If spark plugs are black, dry, or wet, there is a problem with fuel or air delivery. Remember, use only resistor spark plugs and wires.  Next change your oil filter and replace your fuel filter. Install new filter with arrow pointing in the direction of fuel flow then start the engine and check for fuel leaks. Stop engine, tighten connections as necessary. Reset oil maintenance countdown by leaving the engine off and flipping Engine Control switch from Run/Idle to Run three times. 

Every 500 hours you should check and replace your weld cables if necessary. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Never place anything between weld cable terminal and copper bar and make sure that the surfaces of the weld cable terminal and copper bar are clean. 

You will also need your slip rings to be cleaned and your brushes replaced, however this is not a job for the operator. Bring your machine to a factory authorized service agent (like Earlbeck) for this task!

If you need to take a welding certification test, you might be wondering which test do I take? This is the big question. There is not a single welding certification test that will certify you to weld everything. Most welding certification tests are done under the codes written by AWS (the American Welding Society) or ASME (American Society of Mechanical Engineers.) There is a specific code written for virtually every application of welding- AWS has published 240 codes alone. Knowing which code to be certified to is essential, as welders are only certified to weld within the code parameters of the test they have taken.
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There are two common scenarios in which someone will seek certification- you would like to add to your credentials, or it is required for a specific job so let's discuss!

We are always on the lookout for groundbreaking products that can make a real difference in your operations. Meet Oxylance’s Sure Cut System, a game-changer that will revolutionize the way you cut metals!

This system is designed to cut virtually any metal, be it ferrous or non-ferrous, faster and more efficiently than conventional Oxy/Fuel Gas torches or carbon arc gouging.  Requiring no preheating or material cleaning before cutting, it’s a straightforward and cost-effective solution for a wide range of applications. Let's talk about why we love the Sure Cut System and what it can do for you!

With its versatility, safety features, and proven track record in various applications, the Sure Cut System is a must-have for professionals seeking efficiency and precision in their projects. ​Reach out today to upgrade your cutting capabilities with the Sure Cut System: a true time saver when time is money!  

In March 2004, the Maryland State Highway Administration (MDOT SHA) underwent a pivotal change in its approach to welder certification. They discontinued their in-house testing and partnered with the Federal Highway Administration's Mid-Atlantic Structural Committee for Economic Fabrication (SCEF) to establish a regional certification program. Certifying at an AWS Accredited Test Facility (ATF) is now a mandatory requirement for welders working on bridge construction projects in the Mid-Atlantic region, including Maryland.

​No access to main electricity, no worries with Fronius’ AccuPocket. The small, compact 2 kVA generator is perfect for even large scale welding applications. And all without any restrictions on welding power or the quality of the arc! Portable, lightweight, and durable- the AccuPocket makes for the perfect partner on any construction or job site!

Our Favorite Features:

• Battery Powered - This machine can weld up to 18 electrodes (3/32) or up to 124" on just a single charge
• Visible charge level on display
• Only 24 lbs!
• Easy single knob user setting controls
• Rolling wheeled storage case
• Perfect starts with no sticking
• Only needs a 30 minute charge with the Quick Charge feature, allowing you to get started faster!

 Between 10/1/2023 and 12/31/2023, enter coupon code AccuPocket300 during checkout for $300 off the AccuPocket!

The TransPocket redefines flexibility in welding. With integrated Power Factor Correction, your welding leads can be as long as 330 ft long without affecting welding results! The 7-segment display simplifies how you view the parameters and is set back so it’s well-protected. The TransPocket is welding made smarter and more efficient with no loss of power.

Our Favorite Features:

• Anti-stick settings make it easy to safely and quickly remove a stuck electrode
• No matter the extension cord, there is no power loss with PFC
• Timed shut off saves on energy
• Hot & soft start makes it easier to ignite your arc

Between 10/1/2023 and 12/31/2023, enter coupon code TransPocket150 during checkout for $150 off the TransPocket!

The TransTIG 170 is a true multivoltage welder, it brings a wide power supply bandwidth that seamlessly adapts to grids worldwide. Inverter technology adeptly handles voltage fluctuations and low input voltages, ensuring a consistent maximum power output – an invaluable feature, particularly in unreliable power grids!  It will help you hit that perfect stable arc every time- the ultimate welding companion built for the demands of the field

Our Favorite Features:

• Durable plastic carrier and housing keeps everything safe and sound
• Weld for up to 4 mins without a break with it’s generous 40% duty cycle! 
• High frequency ignition detects contact with the workpiece and ignites the arc when you need it

Between 10/1/2023 and 12/31/2023, enter coupon code TransTig225 during checkout for $225 off the TransTig!

The TransTIG 210, like the 170, is a completely digitized TIG DC power source. The operating frequency of the inverter technology makes for a stable arc and precise control. Get maximum efficiency in the duty cycle, the output power and the mains voltage supply with the TransTIG 210!

Our Favorite Features:

• Weld for up to 4 mins without a break with it’s generous 40% duty cycle! 
• TAC simplifies tacking with a single spot- helpful when welding thin sheets without filler metal
• Touchless high frequency ignition easily ignites the arc
• Touchdown ignition for sensitive application areas allows you to avid electromagnetic interference, which can occur during HF ignition
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Between 10/1/2023 and 12/31/2023, enter coupon code TransTig225 during checkout for $225 off the TransTig!

At the heart of the Winco Big Dog Industrial lies a powerful Honda GX630 Engine. If you're someone who expects the best, this generator won't disappoint. The Honda GX630 boasts improved adaptability, quieter operation, and greater fuel efficiency, ensuring you have a reliable power source when you need it most.

Equipped with a YourGen Meter which provides vital information on an LED display, including hours, RPMs, voltage, and frequency readings. It verifies load balance and warns of abnormal parameters or when it's time for an oil change. Another great feature is the auto shut down- in the event of low oil levels, the engine will shut down automatically, protecting the engine from damage. You can rest easy knowing that your equipment is safe!

With its powder coat paint finish and a sturdy wrap-around cradle made of 14-gauge welded tubular steel, it's built to endure. The EPA-approved 15 gallon steel fuel tank eliminates hydrocarbon emissions, making it eco-friendly and efficient. Premium circuit breakers provide a clear indication of a tripped circuit, and each one of these durable generators is load tested before it leaves the facility, so you know you can count on it!

Winco's Dyna Professional is engineered to the same high standards as the generator above, making it the go-to choice for residential and professional applications! Honda's reputation for superior reliability and performance is upheld here with the GX390 engine- designed to power through the toughest tasks with ease.

Stay in control with the YourGen Meter, featuring an LED display that shows crucial information, like hours, RPMs, voltage, and frequency readings. The load bar display verifies load balance and lets you know when parameters go beyond the normal range or when it's time for an oil change. Your equipment is safeguarded with the low oil protection feature. If the generator detects low oil pressure, it automatically shuts down, preventing engine damage and ensuring you’ll get the most out of your investment.

Engineered to provide clean power with less than 5% Total Harmonic Distortion- which means it's safe to run sensitive electronics! And this generator comes with an EPA-approved 8 gallon steel fuel tank design that eliminates carbon emissions, making it environmentally friendly and efficient. 

​The sturdy 1" tubular steel cradle ensures dependable and lasting support for your generator. Winco makes a point out of load testing every single generator before it leaves them so you can trust that yours is ready to perform when you need it most.

A butt joint is a common type of welding joint formed when two workpieces are placed in the same plane and their sides are joined by welding. This type of joint is widely used in pipeline and structure manufacturing due to its ease of preparation and various variations. Some examples of butt weld joints include Single U, Double U grooves, Single V, Double V, Single bevel, Double bevel, and Square.

During the welding process, the area of metal that’s melted is called the faying surface, and it is shaped through edge preparation before welding to enhance strength and appearance. Proper edge preparation is crucial and depends on factors like groove shape, gap width, and layering. Thicker sections require grooves for full penetration welds, while thin sections can achieve this with a square butt joint. The choice between beveled and square edges depends on the application and material thickness. Beveled edges create stronger welds but require more material and time.

Common Defects: Porosity, burn-through, incomplete penetration, and cracking. These defects can be prevented by modification of the welding variables.

A corner joint is created by welding two workpieces at a 90° angle, forming an L shape. This type of joint is straightforward to assemble and typically requires minimal, if any, edge preparation. There are two main types of corner joints: open and closed. In a closed corner joint, one workpiece's edge aligns flush with another's, while in an open corner joint, the edges meet at the corner with a visible gap.

Corner joints are often used for square frame projects. The choice between open and closed corner joints depends on material thickness and the required strength for the application. When welding thinner materials with an open corner joint, consider increasing the travel speed to avoid burn-through. Open corner joints result in a V shape, which may need more welding material based on material thickness. For closed corner joints, grinding the weld face is necessary to achieve a smooth transition from the weld to the base material.

Common Defect: Post-welding distortion. To prevent distortion, consider using a fixture to hold the workpieces securely in place during welding.

A lap joint is created by overlapping two workpieces, and the weld forms at their meeting point. The extent of this overlap depends on the workpiece's thickness, with thicker materials requiring a greater overlap.
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Lap joints offer good mechanical properties, but it's crucial to ensure there are no gaps between the workpieces when welding. In some cases, you may need to choose between a butt joint and a lap joint. Lap joints provide more strength in high-stress areas, but they don't result in a flush contour, making them more visible than butt welds.

Common Defects: Distortion and burn-through. When working with thinner materials like sheet metal, adjusting the amperage and increasing the travel speed can help prevent these issues

A Tee joint is created when two workpieces intersect at a 90° angle. In this type of joint, one workpiece's edge is welded to the center of another workpiece's flat surface, forming a T shape. It's also possible to form a Tee joint by welding a pipe or tube to a base plate. This joint is known for its high mechanical strength, especially when welded from both sides, and it finds applications in various fabrication tasks, including tubing, structural steel, and equipment.

Welding Tee joints becomes relatively easy and require less joint preparation with the right parameters and techniques. It's essential to weld on the side of the joint that would experience stress, ensuring effective penetration. Failure could occur if the opposite side of the joint is subjected to load or impact. Welding on both sides will maximize strength. Tee joints can be conveniently welded in horizontal, flat, vertical, and overhead positions.

When working with a 90° Tee joint, a 45° work angle is recommended to achieve deep penetration on both workpieces. If welding dissimilar metal thicknesses, the focus should be on the thicker material to avoid defects.

Common Defects: Lamellar tearing, which results from restriction within the joint. To prevent joint deformities, you can place a stopper.

Edge joints involve aligning the workpiece edges in a nearly parallel or parallel fashion to one another. These joints are typically applied in situations where the workpieces are not subject to stress. There are various types of edge joints, depending on how the edges are prepared for welding.
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Some of the applications for edge joints would be J-groove, U-groove, V-groove, Bevel-groove, Corner-groove, and Square-groove. These joints offer versatility in welding configurations to suit different requirements.

Common Defects: Poor penetration. To prevent this use a groove edge preparation to allow adequate penetration or improve the overall weld joint rigidity