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Destructive Weld Testing

1/3/2023

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Machinery, automobiles, aircraft, and office/residential buildings all require welding to help society function with safety and ease. While many activities have a margin for error, welding is not one of them. Just imagine the devastating consequences of poor welding on a nuclear power plant!
Thankfully, the welding industry has various means to test the strength of welds before they are used in production. There are destructive tests which involve physically destroying a completed weld to assess its infrastructure; and non-destructive tests, which check for defects and discontinuities without causing damage to the part.
Understanding the different testing methods and what each evaluates gives your quality control team options for ensuring your weld is fit for service. Whether used for failure analysis, welder performance qualification, or sample or research inspections, destructive weld tests detect crack initiation and other defects before it's too late. ​
Fillet Weld Break Test
​

As its name suggests, fillet weld break tests involve breaking a fillet weld that is fused on only one side. The test is most often conducted on a 6 to 12-inch section.
 
The break (destruction) occurs by using a press to apply weight to the unwelded side until the weld fails. The sample is then examined for flaws.

This test is typically used to check for the following defects:
 
·      Slag inclusions
·      Internal porosity
·      Lack of fusion
·      Linear fusion defects
 
Because it reveals discontinuities within the length of the weld, the fillet weld break test is the way to go to determine the EXTENT of a weld’s defects.
Guided Bend Test
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Once again, this test keeps to its name. A welding specimen is bent to a predetermined radius along a wraparound bend test jig or another test machine. Welders can conduct both face and root bend tests using this method, using side bends to assess thicker sections.

Guided bend tests are particularly adept at assessing:

·      Ductility
·      The soundness of welded joints
·      Linear fusion defects

This is also the most commonly used assessment in welder performance qualification tests.

Macro Etch Testing

Macro etch testing is a highly successful test that removes small samples from the welded joint. The samples are polished at their cross sections before a mild acid mixture (which varies depending upon the base material) is used to etch the joint. The etching, with particular focus on the fusion line, provides insights into the internal structure of the weld.

Characteristics that this test appraises are:

·      Fusion (or lack thereof)
·      Penetration depth
·      Cracking and inclusions
·      Internal porosity

To understand the OVERALL weld-length quality of production welds at the cross-section, use the macro etch testing method. 
Traverse Tension Test

The traverse tension test is used to evaluate a welded joint’s tensile properties. The test is conducted by exerting pulling forces on specimens until the joint fails. Welders then divide the maximum load required during testing by the cross-sectional area to read the units of tension per cross-sectional area.

Because tensile properties of welds (which involve ductility and soundness) are vitally important to manufacturing designs, this test is one of the most crucial to the industry.
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Teach to the Test?

In many industries, the concept of “teaching to the test” is generally frowned upon. The thought is that teaching skills exclusively to achieve certain test scores restricts a student’s capacity for creativity and real-world scenarios. However, when it comes to welding, meeting the criteria of the welding code for your application can mean the difference between life and death for customers. 

From its pervasive role in everything from transportation and housing to tools and technology, welding is an integral part of modern society. It is the welding industry’s responsibility to ensure that welded products maintain the integrity to perform their intended tasks.

If you need destructive or non-destructive weld testing, give the Earlbeck Technical Center team a call at (410) 687-8400 and we will help you select and implement the correct test for your product's service. 

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WELDING VARIABLES BASICS

12/12/2022

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Aristotle once noted that “quality is not an act, it is a habit.” This quote is certainly true of welding. While the goal of welding is clear, the alchemy that makes it happen is far from simple. Thankfully, by taking the time to understand and master the variables of welding, it is possible to ensure quality welds on most occasions.

Although not exhaustive, the following list presents 7 influential welding variables. Mastering these will enable more skill and consistency in weld outputs.
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Variables 1 & 2: Amperage and Wire Feed Speed (WFS)
“Amperage” describes the volume and speed at which electricity flows through a circuit. In welding, amperage influences the level of joint penetration that wire feed speed (WFS) will have. The higher the amperage, the greater the joint penetration will be (and vice versa).    Amperage also impacts contact-tip-to-work distances (CTWD). Less amperage will create a greater distance while increased amperage will lessen the distance. In other words, amperage controls the weld penetration of the base metal. Additionally, amperage influences melt-off-rate as well as weld bead appearance (amperage that is too high can result in a dull, flaky weld).

Welders need to keep these factors in mind so that they can ensure the amperage supports their desired WFS speed and level of joint penetration. As with most skills in life, practice makes perfect.
Variable 3: Base Material
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The base material is the metal or alloy that is being welded, soldered, or cut. The following is a list of common types of welding materials:
​
  • Aluminum
  • Cast Iron
  • Copper
  • Magnesium
  • Nickel Alloys ​
  • Steel

​While each of these metals can be used as a base material, it is important for welders to study the different characteristics of each. In order to choose the right metal for the task, a welder must consider factors such as strength, conductivity, flexibility, and heat sensitivity/melting points. For instance, steel is a versatile and strong metal, but can also flake and rust from oxidation; cast iron is not as ductile as other metals; magnesium has flammable shavings. Knowing how each metal responds to different welding methods allows welders to avoid mishaps and ensures a quality, finished product.
Variable 4: Shielding Gas
In welding, shielding gases prevent the molten weld from interacting with gases in the air atmosphere. Protection from this exposure helps to determine arc stability, weld penetration, and mechanical properties of the finished product as well as to prevent spattering and holes within the weld bead.

Each shielding gas has different effects. They can be combined to enhance different properties. Carbon dioxide (CO2), for instance, provides deep penetration, but less arc stability and more spattering.  Adding argon to CO2 mitigates these negatives while also allowing higher tensile strengths and more aesthetic value.

With such benefits at stake, taking the time to learn about the strengths/weaknesses of different shielding gases and combinations will be well worth the effort. Learn more about how to choose a shielding gas for your application here. 
Variables 5 & 6: Travel Speed and Heat Input
The speed at which arc moves along the weld joint is known as “travel speed.” Measured in IPM (inches per minute), changes in travel speed affect heat input in that faster speeds produce less heat. Different base materials react differently to heat, so controlling travel speed is necessary to ensure a good weld. Burn-through, poor penetration, and undesirable weld bead sizes are some of the defects that can occur if the travel speed/heat input are insufficiently matched with the base material.
Variable 7: Voltage
Last but not least on this list, voltage is the variable that adjusts arc length. Higher voltage increases heat and produces a longer and wider arc, while lower voltage produces a shorter, narrower arc. Because voltage impacts the shape of the weld profile and weld bead (in short, everything that is above the surface of a weld), it is important that it is neither too high nor too low. A voltage that is too low can also prevent fusion.

Welders should play around with voltage and adjust as needed. It is important to practice with the same equipment that will be used for projects because the voltage in reality may not always match the voltage reading on the power source.
Putting Everything Together
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In order to become a master of the trade, welders should experience with each variable in isolation (to determine its effects) as well as in various combinations. It is through trial and error that the best possible formula can be determined. In welding, one size does not fit all, and variables that may be detrimental in one case may be perfect for another (e.g. a lower WFS is ideal for shirt-circuit welding). Working to master the parts of the welding process that can be controlled will result more consistently in quality welds.

The Earlbeck Technical Center offers courses that will teach the welding operator how to select the correct variables for their application. To learn more about our courses, click here to get additional details.

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Guide to Choosing Your Stick Electrode

12/1/2022

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​
In order to identify which stick electrode you should use, their is a system of classification that takes the form of numbers and letters printed on the sides of stick electrodes. Always check the welding specification and procedures for the electrode type, especially for critical applications.
​

Here’s how the classification of the AWS system works:

  • "E" indicates electrode.
  • The first two digits represent the weld's minimum tensile strength (in PSI). An example, the number 60 in an E6010 electrode indicates that the electrode will produce a weld bead with a minimum tensile strength of 60,000 PSI.
  • The third digit indicates the welding position(s) for which the electrode should be used. 
    • 1 means the electrode can be used in all positions
    • 2 means it can be used on flat and horizontal fillet welds only
  • The important fourth digit represents the coating type plus the type of current (AC, DC or both) that can be used with the electrode.
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First, select the stick electrode that matches the strength properties and composition of the base metal you will be working with. 

Next, match the electrode type to the welding position (1 or 2) and consider the available power source. Remember, certain electrodes can only be used with DC or AC, while other electrodes can be used with both.

Inspect the joint and fit, then select an electrode that will provide the best penetration characteristics (digging, medium, or light). 

To avoid weld cracking on thick, heavy material and/or complicated joint designs, select an electrode with maximum ductility.

Do not neglect the service condition the component will encounter and the specifications it must meet; low temperature, high temperature, or shock-loading environment for example. A low hydrogen E7018 electrode works well.

Also, consider production efficiency. When working in the flat position, electrodes with a high iron powder content, such as E7014 or E7024, offer higher deposition rates.

For critical applications, always check the welding specification and procedures for the electrode type.

Properties of Electrodes:

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The most common stick electrodes in the American Welding Society (AWS) A5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding include  E6010, E6011, E6012, E6013, E7014, E7024, and E7018.
​​​

​
  • E6010 Electrodes
    • DC power sources only.
    • Deep penetration with the ability to get through rust, oil, paint, and dirt. 
    • Extremely tight arc, ideal for more experienced welders.
    • General-purpose fabrication and maintenance welding. 
    • X-ray quality welds out-of-position also good for vertical and overhead. 
    • Flat beads with distinctive ripples; light slag.
  • E6011 Electrodes 
    • AC power sources/can be used with DC if necessary.
    • Able to use for all-position welding. General-purpose fabrication and maintenance welding. 
    • Produces a deep, penetrating arc with maximum admixture that cuts through metals. 
    • X-ray quality welds out-of-position. 
    • ​​Flat beads with distinctive ripples with light slag. 
  • E6022, E7010, E8010, & E9010
    • DC power source
    • General-purpose fabrication and maintenance welding. 
    • X-ray quality welds out-of-position; good for vertical and overhead. 
    • Deep penetration with maximum admixture.
    • Flat beads with distinctive ripples and light slag.
  • E6012 Electrodes 
    • AC & DC power sources.
    • Solid choice to gap bridging between two joints. 
    • Boasts high-speed, high-current fillet welds when in the horizontal position.
    • Tends to produce a shallower penetration profile and dense slag.
    •  Usually requires additional cleaning.
    • Medium deposit rates and medium penetration. 
    • Smooth ripple-free to even with distinct ripples.
  • E6013 Electrodes 
    • AC & DC power sources.
    • Soft arc with minimal spatter.
    • Medium deposit rates and medium penetration. 
    • Moderate penetration and easily-removable slag. 
    • Used to weld clean, new sheet metal ONLY.
    • Smooth ripple-free to even with distinct ripples.
  • E7014 Electrodes 
    • AC & DC power sources.
    • Produces almost equal joint penetration as E6012 electrodes, but can be used at higher amperages.
    • Designed for use on low-alloy steels and carbon. 
    • The deposition rate increases due to a higher amount of iron powder. 
    • Medium deposit rates and medium penetration. 
    • Smooth ripple-free to even with distinct ripples.
  • E7018 Electrodes 
    • AC & DC power sources.
    • Deemed one of the easiest to use, they contain a thick flux with high powder content.
    • Produces a smooth, quiet arc with minimal spatter and medium arc penetration. 
    • Used by many to weld thick metals like structural steel; also when welding carbon and low alloy steels that require 70,000 PSI tensile strength deposits. 
    • These electrodes produce dense, x-ray quality welds with high-impact properties (cold weather) and can be used on high-strength steel base metals, carbon steel, low-alloy, or high-carbon.
    • Can be used for these applications: low-temperature, high-temperature, or shock-loading environments.
  • E7028 Electrodes
    • AC & DC power sources.
    • Fast-fill, low hydrogen group
    • Welding carbon and low alloy steels that require 70,000 PSI tensile strength deposits. 
    • Produce dense, x-ray quality welds with notch toughness properties.  
  • E7024 Electrodes 
    • Direct and Alternating currents can be used (DC & AC)
    • Deposition rates increase due to a high amount of iron powder.
    • Used by many for high-speed horizontal or flat fillet welds; also slightly downhill position. (15” maximum)  
    • These electrodes perform well on steel plate at least ¼ inch thick or metals that measure over ½ inch thick.
    • Smooth ripple-free beads are flat or slightly convex with minimal splatter and easy slag removal.
  • E6027 Electrodes
    • AC & DC
    • Highest position rates of all electrodes. 
    • Flat, horizontal/slightly downhill position only. (15” maximum)  
    • Smooth ripple-free beads are flat or slightly convex with minimal splatter with easy slag removal.

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weld discontinuities

9/8/2022

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We've compiled a list of the most common weld discontinuities and how to correct them. A discontinuity is a flaw in the weld, but they are only considered to be weld defects when they exceed the limit allowed by the welding code. Learn more about welding codes here. Each code determines the extent of the discontinuity before it is classified as a defect and must be repaired. 

For example, if a welding code acceptance criteria allows for undercut up to 1/32" deep and the welding inspector measures undercut that is 1/16" deep, then that weld is rejectable. If the undercut measured was 1/32" or less, then the weld is acceptable. 

All defects are discontinuities, but not all discontinuities are defects. Understanding this forms the key to the proper analysis of any weld performed in accordance with the requirements of a welding code or specification. 

Porosity

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Porosity is a cavity-type discontinuity caused by trapped gas in the weld during the solidification of the weld metal. 

Possible Causes
Long Arc Length
Dirty Base Metal
Inadequate Gas Coverage

Possible Cures
Use Proper Arc Length
Clean Base Metal
Check for Proper Gas Coverage

Undercut

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Undercut is a groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal.

​Possible Causes

Improper Welding Technique
Excessive Voltage
​Too low wire feed speed

Possible Cures
Reduce Arc Length
Reduce Travel Speed
Use Proper Electrode Angle

Incomplete Fusion

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Incomplete fusion is a weld discontinuity in which fusion didn't occur between the weld metal and the fusion faces or the adjoining weld beads.

​Possible Causes
“Cold” Welding Procedures
Travel Speed Too Slow
Travel Speed Too Fast

Possible Cures
Increase Current
Use Proper Travel Speed

Incomplete Joint Penetration

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Incomplete joint penetration is a joint root condition in a groove weld in which weld metal does not extend through the joint thickness.

​Possible Causes

“Cold” Welding Procedures

Travel Speed Too Slow
Travel Speed Too Fast
Improper Joint Detail

Possible Cures
Increase Current
Use Proper Travel Speed

Excessive Reinforcement 

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Excessive reinforcement is a discontinunity caused by the weld being too big or has too much build up.

​Possible Causes

Travel Speed Too Slow
​“Cold” Welding Procedures
​

Possible Cures
Increase Travel Speed
​Increase Current 

underfill

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Underfill is a groove weld condition in which the weld face or root surface is below the adjacent surface of the base metal.

​Possible Causes

Insufficient Weld Metal
​

Possible Cures
Reduce Travel Speed 

Concave Root Surface (Suck-back) 

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Concave root surface is a groove weld exhibiting underfill at the root surface.

Possible Causes

Too Much Current
Arc Length Too Long
Root Face Too Small
​

Possible Cures
Reduce Current
Maintain Proper Arc Length
Use Proper Joint Fitup 
​

Overlap

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Overlap is extra filler metal that spreads out beyond the weld bead.

Possible Causes

Travel Speed Too Slow

Possible Cures
Use Proper Travel Speed​

Arc Strikes 

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Arc strike is considered a weld discontinuity resulting from an arc.

​Possible Causes

Improper Welding Technique
​

Possible Cures
Initiate Arc Inside the Weld Joint 

Slag Inclusions

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Slag inclusions are a weld discontinuity consisting of slag entrapped in weld metal or at the weld interface.

Possible Causes
Improper Welding Technique
​

Possible Cures
Use Correct Welding Technique
​Clean Weld Between Passes

Earlbeck Technical Center

Still need some help? The Earlbeck Technical Center offers welder training and weld testing services in the Mid-Atlantic Area. Not only do we conduct testing services to any code, but we provide training to ensure you are ready to take your certification test. Click here to learn more. 

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IPG Photonics LightWELD handheld Laser welder Benefits

6/2/2022

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Earlbeck Gases is now the IPG Photonics mid-Atlantic distributor for their line of LightWELD handheld welding systems- the best laser welding machines on the market. 

LightWELD’s advanced fiber laser technology allows for an easier, faster, and more aesthetic welding process than its traditional counterparts. This lightweight, handheld unit can weld up to four times faster than other welding systems. Contrary to MIG and TIG methods, a wide-ranging assortment of thicknesses and materials can be welded, including those with dissimilar electrical conductivities. 


With an impressively low heat input, the heat-affected zone is minimized—creating a higher-quality finish with zero distortion. This also means less undercut or burn-through, which makes for a welding experience that’s the opposite of frustrating. Fabricators will also benefit from a more streamlined process. With LightWELD, welding fixtures are simpler, and there is no pre- or post-weld clean up. 

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Controls are intuitive and come with built-in factory presets, allowing new welders to learn within a matter of hours which is especially important in today’s labor market. John Morash, founder and CEO of the Morash Institute of Welding, said of LightWELD: “In my forty-one years in the business, I have never seen a welder that allows beginners to make welds like seasoned pros!”

With LightWELD’s enhanced flexibility and precision, as well as its easy-to-learn controls, users will undoubtedly reduce labor costs—and in turn increase their production and profits.

If you have any questions or would like a demo, please fill out the contact form below!

    Handheld Laser Contact Form

Submit

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2022 Welding career outlook

12/30/2021

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If we had to guess, it would be safe to say that we are all ready for 2021 to come to a complete close. Let’s just fuse the joints and keep burning. 

As we welcome and embrace the new year of 2022, let’s look at the projection for welders, career opportunities, and a few interesting events that have taken place since we began our journey into 2020. Read on more for inspiration for years to come!

​To the current and prospective welders, there will be a shortage of approximately 400,000 welders by 2024. The shortage is so large due to the boomer generation retiring from the industry. Welders can earn approximately $44,000 per year as a median projection and although welding as an industry typically requires certification, the welding career can be achieved with only a GED or High School Diploma regarding formal education. In 2019, there were 438,900 welding jobs available, and with the projected shortage of welders in the field, there will be more opportunities to come.

There have been rumors about automated welding process replacing human welders, but that is not something to worry about. Fortunately for us humans, we can withstand certain conditions; and have the capability to accomplish welding projects that an automated process cannot. There will be opportunities for welders to learn how to operate the automated processes, as they require a welding operator to oversee and control the process. If anything, automated welding processes will provide more diverse opportunity within the industry. 

Here’s a list of some welding career opportunities based on the industry being served, first listing the top five: 

1. Pipe Welding: These welders are in high demand, as they serve the gas, oil, and water utility companies. Welders will need to work on the pipelines carrying these valuable resources. 

2.  Aerospace Welder: This focuses on the equipment and technology used in airplanes. This type of welding is challenging, as there are many different welding processes and applications that are used and may also require off-ground welding. 

3. Military Support: Welding in the military is not much different than civilian welding but requires the typical protocols of being in the military. Example: basic training is required, and it is within the various branches. One perk of pursuing this route is that there is no experience necessary, and the military will train. 

4. Underwater Welding is challenging, as you can imagine. The underwater welder will have to accomplish the task at hand, while also attending to the risks associated with diving and being in the depths of water. 5. Certified Welding Supervisor monitors the welder, welding projects, ensures safety, and inspects the completed project for safety and compliance according to the appropriate code. 

6. Autobody Technician / Custom Car Builders: When vehicles break down, damaged parts will need to be welded for repair, or to cut (remove) and install the appropriate part for a functional vehicle. 

7. Shipbuilding and Repair: Inspects vessels and complete any necessary repair. (This may require travel along with the ship). 

8. Rig Welders (Oil and Construction): This facet of welding is one of the biggest opportunities for welding in the oil and gas industry. Welders save companies significant amounts of dollars by repairing the rigs as they begin to show ware. This is physically demanding, as the welder will need to be on the job for a long period of time. 

9. Jewelry Designer: For the individual that has a desire to create beautiful pieces that are intricate and delicate. They would also repair and resize the jewelry. 

10. Boilermaker: assembles, installs, and repairs boilers or large-scale containers to hold gas or liquids 

Other types of industries for welding are: Industrial Maintenance Welders, Structural Steel Welders, Tool and Die Makers, Sheet Metal, Construction, and Motorsport.


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To intrigue you even more, let's check out how interesting a career in welding can be and the opportunities that lie ahead.

At NASA’s Michoud Assembly Facility in New Orleans, technicians from Lockheed Martin began welding the Orion Spacecraft, intended to land the first woman and next man onto the moon. The pressure vessel, being the primary structure, is comprised of seven machined aluminum alloy pieces that will provide an air-tight and habitable environment, while the astronauts travel through space and to withstand the harsh elements. The welding technology used is a Friction Stir Welding process. This process does not melt metal but causes friction that joins the two facing work pieces using a non-consumable tool.
​
To read more of this story, you can check it out here.

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Another recent accomplishment in the industry is the repair of the vintage aircraft called “The Chipmunk DHC-1”, which is named after the Canadian squirrel. This aircraft was a post war vintage aircraft developed in 1946 by De Havilland Aircraft of Canada; and as time moved forward, it was accessible to civilians. Repairing the aircraft was a challenge without the proper technology and sourcing parts was a financial endeavor. There have been many challenges to achieve this repair; and took over two years of research to accomplish since the aircraft is not favorable to the increasing temperatures caused by welding. The technology used is Cold Spray and known as Supersonic Particle Deposition (SPD) which uses either Nitrogen or Helium gas to propel metal particles to the aircraft parts, resulting in bonding of the metal. This process restores the part to its original blueprint dimensions, giving the Chipmunk DHC-1 another chance to soar the skies! 

Earlbeck Gases & Technologies is here to assist in the beginning of your welding journey and offers many different classes to achieve the goal of becoming a welder. It is crucial that we bridge the gap for welders and the industries served to ensure the sustainability of our world. Even though things seem uncertain, the welding world is the complete opposite. May we raise our torches and “toast” to the future that is as bright as the sparks we produce from our torches!

Author

Julia Brown, Customer Service Specialist/ Marketing Assistant 

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How to Choose Flux for your Soldering or Brazing Application

3/5/2019

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Soldering Application
Let’s flux about it…
 
You’ve decided to make a repair; you have your soldering gun or brazing torch ready to go, but it hits you! “I don’t have any flux!”
Not to worry, we will help you choose what flux is right for you, but first you will know the difference between the applications.
 
 “What’s the difference between soldering and brazing?”
The American Welding Society (AWS) defines brazing as a process which involves a filler metal that turns to liquid above 842 degrees Fahrenheit (450 degrees Celsius). Brazing applications are a mechanically strong joint. You would typically see this application being used in the automotive industry, for jet engines and in HVAC. You may not know, but your cookware and utensils are also put together using this application. Did you ever wonder how your cookware was so durable? Probably not, but it’s still good to know!

Soldering also involves a filler metal but turns to liquid below 842 degrees Fahrenheit (450 degrees Celsius). This makes the joint electrically strong and can withstand any electric currents running through. If you are soldering any type of electronics, you will need to keep in mind that the temperature needs to stay below 842 degrees Fahrenheit so that your electronics don’t burn up. Yikes! 
Since soldering has a lower processing temperature, the joint is not as strong, compared to the brazing application. This is sometimes the most desirable application, because it has a lower liquidus state compared to brazing.

Of course, always follow your procedure or spec sheet for the proper application for every job!
 
Now we know the difference between the applications, but we need something else to complete the job. “We need flux!”

“What is flux?”
Flux is a chemical cleaning agent, flowing agent, or purifying agent. Flux is used in extracting and joining metals and is crucial to promote melting of the filler metal.
​
“Do I even need flux?”
Yes. It is imperative to use flux for the following reasons:
  1. Removes oxides from metals to be joined (you will still need to clean your metals prior to application).
  2. Prevents oxidation after completion.
  3. Improves “wetting out” characteristics and heat transfer, which allows the filler metal to flow and not ball up.

“What type of flux do I need?”
There are many options available, but they all have their advantages and disadvantages.  You will have to take many variables into consideration, before you grab the nearest flux on the shelf. Not all flux is created equal!
Here are the things you need to know, in order to find the right flux for the job:
  • Application
  • Process
  • Type of metals to be joined
  • Filler metal
  • Thickness
  • Diameter of filler metal
  • Desired appearance/cleanliness
  • Any additional information that is relevant for the job

brazing
​You will have choices when it comes to the type of flux you will need. Here are some types that are out there:
  • Flux coated filler metals
  • Rosin core solders
  • Powder
  • Liquid
  • Paste
  • Gel
  • Flux that is “injected” into the flame from the fuel supply
 
 Solder Fluxes:
No Clean Flux- Residue, if any, is minimal and will “vanish” from the heat produced. If residue needs to be removed, it will require solvent cleaning. It’s very hard to remove and could become an issue because it can interfere with electronics. The residue left behind from the flux is conductive.                  Typical primary ingredient: Isopropanol

Rosin Flux- The reaction between the flux and the metallic oxides on the joint metals make the flux flow easily and provides the cleaning required to “wet” the joint. Rosin flux becomes inert when cooled and solid. If electronics heat up enough to make the residue liquid, the acid can start deteriorating connections. Residue can be removed with alcohol. Typical primary ingredient: Rosin (tree sap)

Water Soluble Flux/Organic- Highly acidic and corrosive. Residue should always be removed when complete. Clean with water, steam, or water-based cleaning product. Typical primary ingredient: Isopropanol
 
Brazing Fluxes: 
General Purpose Powder Flux- Active range 1400-2200 degrees Fahrenheit. Use with low fuming Bronze, Nickel Silver, Copper base alloys, Steel and Cast Iron. This is the same flux that is coated on flux Bronze. Typical primary ingredient: Boric acid, Borax

White Flux- Low temperature (1050-1600 degrees Fahrenheit) silver brazing. This flux is used with most ferrous and non-ferrous metals and not recommended on Aluminum, Magnesium, or Titanium. Typical primary ingredient: Boric acid, potassium fluorohydroborate

Black Flux- High temperature (1050-1800 degrees Fahrenheit) silver brazing. Used on heavy parts where overheating or prolonged heating may occur. This flux is recommended when brazing stainless steels. Residue can be more difficult to remove.
​Typical primary ingredients: Boric acid, potassium fluorohydroborate.

Aluminum Flux- A powdered flux designed for use with aluminum alloys (915-1115 degrees Fahrenheit). You can apply this by sprinkling on dry, mixed with water or alcohol to form a paste. Typical ingredients: potassium chloride, sodium chloride.

Flux Injected in Flame- This flux is introduced into the fuel gas and passed through flame. This increases strength, reduced filler metal consumption, minimal post braze cleaning, quicker braze times, increased penetration, and can cut costs by 40%.
Typical primary ingredient: Trimethyl borate.

Hybrid Fluxes- Some manufacturers have hybrid fluxes available for difficult applications. Brown fluxes have been tested to work like black flux, but easier to remove residue.
 
Although there is no “silver bullet” when choosing the appropriate flux, you may find that multiple types of flux are needed but testing and evaluating may be required for best results. Please contact an Earlbeck Gases & Technologies Representative to help determine the best flux for your job!

Brian Dressel

Account Manager at Earlbeck Gases & Technologies

7 Comments

How to select tungsten for TIG welding

11/8/2018

33 Comments

 
Weldmark Tungsten
When it comes to TIG welding, the most commonly asked question is “What tungsten do I use?” As we know, welding equipment is constantly evolving. At one point in history, the most commonly used power source was known as a rectifier machine. Today, equipment is more commonly inverter based, which gives the welder more control of the arc.

There are a few things you must determine before selecting a tungsten electrode such as:
  • Type of material being welded
  • Type of weld
  • Welding output (AC or DC)
  • Material thickness
  • Amperage range
  • Type of welding power source, transformer/rectifier or inverter

Metals such as carbon steel, stainless steel, titanium, chromoly, brass, and copper will be welded using Direct Current with the electrode negative.  Generally, aluminum alloys are welded using Alternating Current (AC).

Pure tungsten (green stripe), for years was the best choice for AC welding, but with the industry shift to invert based machines, with advanced squarewave technology, rare earth tungsten such as Ceriated (gray stripe) and Zirconiated (brown stripe) are an option.

The most commonly used electrodes today are 2% Thoriated (red stripe).  Thorium has great arc start characteristics and allows for higher current carrying capacity. Although, if thoriated tungsten is used in the AC mode, the tungsten tends to split and get nodules around the electrode instead of a nice round ball. In return, this gives you an unstable arc and inconsistent heat input. It can also cause tungsten spitting giving you impurities in your weld. 

Also, choosing the proper grind angle, constant current range or pulsed current range will affect the electrode current range. Example .040 has range from 2 to 60 amps, .093 has range from 12 to 250 amps and .125 has range from 20 to 350 amps.

tungsten selection chart

Type of Tungsten
Pure

Ceriated


Thoriated 1.7 to 2.2%


Lanthanated 1.3 to 1.7%
​

​Zirconiated  .15 to .40%   
Color Code
Green

Gray



Red
, Yellow


Gold
, Black, Blue
​

​Brown
Remarks
Good arc stability for AC.  Least expensive.

Easy arc starts, and long life.  Replacement for thoriated.

​Higher current capacity, greater arc stability, difficult to maintain balled end on AC.  

Easy arc starts, high current carrying capacity, similar to thoriated.
​
Excellent for AC, good arc starting, limited contamination of weld.

Daryl Kehr

Account Manager at Earlbeck Gases & Technologies

33 Comments

What are the types of welding joints?

8/17/2018

8 Comments

 
Picture
Picture
Figure 1 Butt Joint
Picture
Figure 2 Lap Joint
Picture
Figure 3 T Groove
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Figure 4 T Fillet
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Figure 5 Corner Groove
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Figure 6 Corner Fillet
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Figure 7 Edge Joint
AWS A3.0(2010) Standard for Welding Terms and Definitions defines a weld joint as “the junction of the workpieces that are to be joined or have been joined.”  The welding codes recognize two basic types of joints. They are grooves and fillets. There are several variations of each, however, the easiest way to tell them apart is where the weld is going in relation to the two workpieces. If the weld is between the two workpieces, it is a groove weld. If the weld is beside the two workpieces, it is a fillet weld.

Groove welds extend through the thickness of at least one of the workpieces. The most common groove weld is known as a butt joint (Figure 1). This joint is formed by taking the two workpieces and “butting” the ends together. The weld will be placed in between the two workpieces. When the weld extends completely through the thickness of the joint, it is called complete joint penetration (CJP). When it extends only part of the way through, it is called partial joint penetration (PJP).

The other type of joint is a fillet weld. As mentioned earlier, fillet welds are placed beside the junction of the workpieces. One of the most common fillet welds is the lap joint (Figure 2). This joint is formed by laying one of the workpieces on the other and welding where the edge of the first meets the side of the second.

Another common joint is the T joint. This joint is formed by butting the edge of one workpiece against the side of the other making a T shape. T grooves are welded through the thickness of the one workpiece (Figure 3) while T fillets are welded beside where the two workpieces meet (Figure 4).

Corner joints are very similar to T joints. The only difference is the intersection of the two workpieces does not occur in the middle of the one but at the end or “corner”. Corner grooves are represented in Figure 5. Corner fillets are represented in Figure 6.  

​The last joint is the edge joint (Figure 7). It is formed by laying the sides together so that the edges are next to one another. The joint is then welded along the two edges. Edge joints have partial joint penetration.

Ben weatherford

Welding Engineer and CWI at Earlbeck Gases & Technologies

8 Comments

What is a welding contact tip?

6/9/2018

18 Comments

 
Picture
Contact tips are highly misunderstood components in a welding gun setup. Choosing the correct contact tip for your welding application and understanding how to keep it performing at its best are just as critical as anything else needed to produce a quality weld.

Using a contact tip that is too big or too small can create problems such as microarcing, overheating, friction, and wire jamming—all of which can lead to wire burnback.

Contact tips are one of the most frequently misunderstood and most often replaced components of a welding gun setup. The contact tip is responsible for guiding the wire and transferring the current from the conductor tube—sometimes referred to as a swanneck or gooseneck—through the filler wire and ultimately to the workpiece. Its critical functions include current transfer and wire targeting.

Contact tip size determines what wire size you can use and the amount of filler material that will be distributed during welding. When a contact tip begins to wear, the through-hole elongates and loses electrical conductivity, which greatly affects the gun’s ability to transfer current to the welding wire. Additionally, the tool center point (TCP) begins to fluctuate as the wire dances around inside the now oversized tip. These conditions lead to poor arc starts, lower penetration, and decreased weld quality.
​
Choosing the correct contact tip for your welding application and understanding how to keep it performing at its best are just as critical as choosing all the other components and parameters needed to produce a quality weld.

Common Contact Tip Types
Four types of contact types are most commonly used in welding applications, and each has its pros and cons:

#1: Standard Copper Contact Tip (E-Cu)
A standard copper contact tip has a relatively high current transfer rate at greater than 55 S/m* electrical conductivity, and it is used mostly in hand-held welding applications.
Although standard copper offers the highest conductivity of all of the standard alloys, it is more susceptible to mechanical wear than other materials. As a raw mineral, copper naturally is relatively soft, which means it makes current transfer easier, but it also means the material has a lower melting point. As the temperature rises in an E-Cu tip, it becomes softer than the wire that is being fed through it. As the copper softens, the wire wears and deforms the internal diameter of the tip. This prevents the wire from contacting the tip correctly, which decreases conductivity and leads to arc-start issues, burnback, and poor welds.
The E-Cu tip is usually the most affordable, so it’s generally an acceptable trade-off to frequently replace it when precise wire targeting is not critical.

#2: Copper-Chrome-Zirconium Contact Tip (CuCrZr)
A copper-chrome-zirconium tip generally is used in automated and robotic welding applications where precise TCP is needed and high duty cycles occur. Although there is some decline in electrical conductivity compared with the standard copper tip (50 S/m), it is sufficient for most steel applications.
However, since CuCrZr alloy softens at a much higher temperature, it tends to have a longer life span than standard copper tips. Generally speaking, the tip maintains its shape up to approximately 932 degrees F versus 500 degrees for E-Cu. Therefore, the higher-density material leads to a lower wear rate and increases the tip’s performance and productivity.
For hot wire feeding processes in laser optics,  copper chrome zirconium are must-use because of their ability to hold up to hot wire feeding processes.

#3: Silver-Plated Contact Tip
Over the years technological advancements in contact tips have revealed that silver plating the interior and exterior of a contact tip further enhances its overall performance.
When a contact tip begins to wear, the through-hole elongates and loses electrical conductivity, which greatly affects the gun’s ability to transfer current to the welding wire.
Silver is more conductive than copper (62.1 S/m), which reduces micro-arcing, extends contact tip life, improves arc starts, and provides consistent weld quality. Silver is approximately 17 percent denser than copper and it has a higher melting point. Silver’s shiny surface helps to reflect heat. As a result, spatter doesn’t adhere to the tip as easily and it doesn’t wear down quite as quickly. In fact, the life span of a silver-plated contact tip can be nine times longer than that of a standard precision-drawn copper tip.
With significant improvements in material, a silver-plated contact tip can cost up to 50 percent more than the standard non-plated CuCrZr tip. Welders who choose to use a silver-plated contact tip usually do so for one reason—less welding downtime. The more the welding robot welds, the greater the throughput. Based on the overall longevity, current transfer, and quality of material, the silver-plated tips are an excellent choice for automatic and robotic welding applications.

#4: Heavy Duty Silver-Plated CuCrZr Contact Tip
Using a process called dispersion-hardening, which basically keeps the properties of metal from dispersing at elevated temperature, the Heavy Duty Silver-Plated Contact Tips can last even longer than the Silver-Plated contact tips noted above.
This make of contact tip carries a hardness value of 180, and won't experience wear until the contact tip temperature reaches upwards of 800 degrees Celsius. Because of it's conductivity, it will also experience a lot less spatter adhesion than copper or non-plated copper chrome zirconium.
Heavy Duty Silver-Plated are always made using CuCrZr contact tips as the base because it combines the better hardening of the copper chrome zirconium with the superior conductivity of the silver. This produces an overall better electrical conductivity profile while still being harder. They are more expensive than the standard ones, but have a low cost of ownership in right application - typically heavy amperage robotic processes.

#5: Stainless Steel Contact Tip X8CrNi18-9 
These types of contact tips only really have an application in laser optic processes. Stainless is good to use for Cold Wire Feeding processes. Steel equal poor electrical conductivity, but it does have good wear resistance. Stainless steel is also harder than copper, so there's usually less wear experience in the contact tip bore.
Stainless steel contact tips are recommended when using copper wire in laser optic processes. If you use Aluminum, it would be better to look to copper or copper chrome zirconium, because this contact tip profile is often too hard for a soft aluminum wire profile.

Advice to Common Contact Tip Problems
Once you’ve matched your contact tip to your welding application, there are a few things you can do to make sure you are getting the most out of it and not inadvertently creating problems that could decrease its life span or effectiveness.
  • Let the torch cool before you change a contact tip. A hot torch can make changing a contact tip very difficult and hazardous. The presence of heat makes it easier to cross-thread the new contact tip, ruining not only the tip, but also the torch neck.
  • Use the correct tip size. Using an oversized tip results in poor current transfer; increased microarcing; and hotter tip temperatures, which lead to wire burnback. Using an undersized tip increases friction and causes the wire to jam in the tip or feed erratically, which also results in wire burnback.
  • Properly tighten the tip. A contact tip that has not been tightened down correctly causes poor current transfer, microarcing, and overheating. When this takes place you will most likely experience erratic wire feeding, poor arc starts, and burnback of the weld wire into the tip.
  • Read your tip’s appearance for problems that you can’t necessarily see. A contact tip that has turned blue or purple is generally a sign that you have a poor connection (including the ground), your consumables are too big, or you have exceeded the torch’s amperage rating or duty cycle. In severe instances the contact tip’s exterior surface will become covered in scale.

Matthew sciannella

Marketing Manager for ABICOR BINZEL
This blog post is reposted with permission from ABIBLOG

18 Comments
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