​In today’s fast-paced world of manufacturing, companies are constantly seeking to increase efficiency to remain competitive. One technology that has been making waves in the industry is collaborative robots, or cobots. Cobots are designed to work alongside human workers to improve productivity and safety in the workplace. Welding applications, in particular, have greatly benefited from this technology with the emergence of welding cobots. In this article, we will delve into what welding cobots are, how they work, their benefits, and their cost.

What is a welding cobot?

A welding cobot is a collaborative robot programmed to perform welding tasks in conjunction with human workers. They are not meant to replace your welding workforce as they still require an operator to program and monitor the welding process but it enables your welders to increase productivity and weld quality.

Unlike traditional welding robots that are mounted on a stationary base, welding cobots have a compact design and can be easily moved between different workstations. They are equipped with advanced sensors, cameras, and AI software that enable them to work safely alongside human workers without the need for safety barriers.

How do welding cobots work?

Welding cobots have a robotic arm that is capable of performing a variety of welding techniques, such as MIG, TIG, and spot welding. They are fitted with specialized welding torches that can enable them to weld a wide range of materials, including steel, aluminum, and stainless steel.  The welding operator needs to train the cobot on the weld that needs to be made, and these welding programs can be saved if a job needs to be repeated.  Once the weld process is set up and programmed, it creates a consistent weld every time. 

What are the benefits of Welding Cobots?

The major benefits of welding cobots include improved safety, increased productivity, and enhanced accuracy. By using welding cobots, companies can reduce the risk of accidents and injuries. Welding cobots can also work faster and more efficiently than human workers alone. Unlike human welders who require breaks and rest, welding cobots can work continuously for extended periods, improving productivity and reducing downtime. Another advantage is the high level of accuracy that welding cobots can achieve. Cobots are equipped with advanced AI software that can ensure precise positioning and accurate welding results. Most namely. with a cobot you can save almost 60% in time and 70% in production costs. 

What are the applications for Welding Cobots?
They are a great solution for  high-mix job shops, repair & manufacturing, part resurfacing & reconditioning, roof & bridge trusses, mechanical contractors & pipe shops, agricultural equipment, and steel fabricators & metal service centers.

What is the Cost of Welding Cobots?

The cost of welding cobots varies depending on their size, capabilities and features. On average, a welding cobot can cost anywhere from $50,000 to $100,000 or more. While this may seem expensive, it is important to consider the long term cost savings and benefits that come with investing in a welding cobot. These include increased productivity, improved quality, and reduced labor costs. Companies should also take advantage of government grants and financing options that are available to help offset the cost of upgrading to the technologies of Industry 4.0.

Welding cobots are revolutionizing the manufacturing industry by improving safety, increasing productivity, and enhancing accuracy. While the initial investment may seem daunting, the long term benefits and cost savings make it a worthwhile investment for any manufacturing company. By utilizing welding cobots, companies can remain competitive and stay ahead in the ever-evolving world of manufacturing.

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. ​

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.

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. 

​

​

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

Possible Causes
Travel Speed Too Slow

Possible Cures
Use Proper Travel Speed​

​

​

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.

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!

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

​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!

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.

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.