Our comprehensive welding program provides our students with the skills they need to succeed on the job- our intermediate and advanced classes include certification tests that make students job-ready out of the gate! But securing a welding job requires more than technical skills—it’s about showing potential employers that you’re reliable, safe, and a good fit for their team. So here are some tips to help ensure your welding interview goes smoothly, allowing you to showcase your skills and land the job you want!

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

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

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

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

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

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

Here are a few practical tips:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In recent years, technological advancements have revolutionized the welding industry, and one such innovation that stands out is heat induction machines. This technology boasts nearly two decades of successful applications across all kinds of industries such as industrial and construction welding, refineries, chemical plants, pipeline construction, shipbuilding, and more. The process plays a critical role in welding applications that demand preheating to bridge the temperature gap between the welding arc and the base material. By doing so, it not only decelerates the cooling rate of the weld but also reduces hydrogen presence, significantly lowering the likelihood of cracking and weld failure.

Induction heating stands out for its ability to drastically cut down on time and ensure uniform temperature control when preheating or post-weld heat treatments are required. It also improves safety and weld quality, marking it as an invaluable tool for time and cost savings!

Induction heating helps the process by preheating the base material, or at least the area around the weld joint, to a precise temperature before starting the weld. This method employs electromagnetic fields to heat the workpiece. Basically the welder can place the tools on or around the conductive object and the magnetic field will produce eddy currents within the metal, which agitate the molecules and creates heat! This makes the object itself the heat source, rather than the heating equipment.

This precise heating mechanism allows for uniform temperature distribution, minimizing distortion and preserving the integrity of the workpiece. And on top of that, there is much less safety risk for the welder compared to the slower, more cumbersome resistance or open flame methods- ensuring an overall more cost-effective heating solution.

Not only does this system stand out for it's ease of use, speed, safety, and cost-efficiency but it's also engineered to work seamlessly with existing welding power sources- simplifying operations and reducing expenses! Companies can internalize preheating processes using on-site welding power sources, often heating a joint to the required temperature in 20 minutes or less!

These heaters are compatible with a variety welding power sources, including all XMT® 350 FieldPro™ models, Miller engine-driven welders/generators with ArcReach technology, and any Miller power source capable of operating a Smart Feeder. 

Induction heating has emerged as a versatile and efficient solution across a broad spectrum of industries and applications, showcasing exceptional flexibility! We all know it excels in scenarios like preheating roll pipe in fabrication shops but it can also play a pivotal role in enhancing operational efficiency and safety in many other industries and applications. Beyond the typical application in pipe welding, induction heating can be used for flat plate and other unique geometries.

Induction heating finds its application in preheating and maintaining weld temperatures, hydrogen bake-outs, post-weld heat treatments, shrink-fit processes, and more. Industries benefiting from this technology include oil and gas, structural, power plants, petrochemicals/refineries, process/power piping, pressure vessels, shipyards, and mining. 

Exploring beyond traditional applications reveals induction heating's potential in fields like heavy equipment construction and maintenance and repair of mining equipment. For instance, overcoming challenges such as the heat sink effect of flowing oil in oil pipeline maintenance or achieving more efficient and safer preheating methods in natural gas pipeline construction. Similarly, in power plant construction, switching to induction heating from less reliable methods has resulted in faster heating times and reduced construction delays.

These examples hint at the broader possibilities for applying induction heating across various settings, emphasizing its role in not only meeting but exceeding the operational and safety standards of today's industries. Whether for complicated part geometries or demanding environmental conditions, induction heating offers a promising avenue for efficiency and innovation.

As every tradesperson knows, understanding the total cost of ownership of new equipment is a crucial step before committing to the purchase. If you're in the market for a portable plasma cutting system, it’s important to consider more factors than just the initial expense. The sticker price of a plasma cutter is merely the starting point- and opting for the cheapest option might just lead to higher costs over time.

Conducting a Total Cost of Ownership, or TCO analysis might seem daunting, but it’s easier than you think for plasma cutters. Since it can be easy to overlook certain aspects that could unexpectedly impact your budget, we’re here to breakdown the key factors of consideration. Strategically planning for these potentially overlooked expenses will maximize cost-effectiveness and help you achieve a quick return on investment! After doing these calculations ourselves, we find that the best long-term return on investment is Hypertherm’s Powermax line- read on to find out why we chose the Powermax and how you can figure out what works best for you!

The unfortunate truth is, opting for a portable plasma system that doesn't fully meet the requirements of the job, just to save on initial costs, can lead to increased production expenses that accumulate faster than you'd think!
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In choosing a plasma cutter, it's critical to weigh the expected return on investment against the potential revenue generated by the system's productivity. Imagine a scenario where a single, well-chosen, high-performance plasma system performs the tasks of two or three inferior systems over its lifespan, or eliminates rework of parts due to dross/slag. The savings from such efficiency can be seen quickly, especially when it comes to consumables. The durability and consistency of cut quality over the lifespan of consumables play a significant role in both productivity and operational costs. Hypertherm's Powermax systems are known for their extended consumable life, coupled with consistent cut quality- keeping your operational costs down.

While cutting initial costs by choosing a lesser known supplier might seem like a good way to save, sometimes this means you’re stuck with poor quality support and service. Downtime for repairs or maintenance can directly impact your bottom line if parts are not readily available for repair, sometimes even making it impossible to get your machine back into working service. Since avoiding mechanical issues altogether is nearly impossible in this industry, opting for a plasma system that is both reliable and backed by a respected dealer can significantly affect your operational efficiency.

Hypertherm stands out with its global network of skilled partners- Earlbeck being one of them This network offers service and support centers across the US, designed to minimize downtime and ensure your plasma system is back in action as quickly as possible. This level of service is something you're unlikely to find when purchasing a budget plasma cutter from large retail chains or online marketplaces.

To gauge the operating costs effectively when comparing different plasma systems, let’s focus mainly on two things: the cost per operational hour and the cutting capacity per hour. This calculation requires knowledge of a few key factors:
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1) the lifespan of consumables or cartridges as provided by the manufacturer
2) the price of these consumables or cartridges
3) the system's duty cycle
4) the cutting capacity within an hour

All of these must take into account both the duty cycle and the cutting speed for the specific thickness of metal being addressed. Armed with this data, it becomes possible to accurately estimate the cost per meter or foot of cutting by also considering the operator's labor cost.

Hypertherm has played a pivotal role in the plasma cutting industry’s evolution over the last 50 years, holding over 100 patents in plasma technology! Their innovation is driven by a commitment to developing customer-focused solutions that not only enhance the longevity of torch consumables and cartridges to lower overall operational costs but also deliver unparalleled electrical efficiency for more cost-effective operations.

Their dedication to precision and efficiency is evident in the creation of application-specific torches and consumables, ensuring the right tool is used for the right job. Advancements in tech have led to significant gains in productivity, operating speeds, ease of use, and cut quality. Plus their products have the ability to integrate smoothly into automated or robotic cutting systems. Designed, manufactured, and tested for high reliability, these plasma cutting solutions ensure that you’ll spend more time working and less money replacing parts and consumables.

Another part of the total cost of ownership is choosing a configuration that not only meets your current needs but also anticipates future demands.

First you’ll need a clear understanding of the intended applications. Depending on what you need now and will need later, you’ll want to look for something capable of handling a diverse array of tasks. The Powermax plasma systems are known for their versatility- they’re capable of cutting, gouging, and marking, in both handheld and mechanized modes. This level of versatility may not be available in all competing systems- some may fall short in certain categories, making your new tool less useful than you thought. Feel free to discuss your specific needs and future plans for the plasma system with us- we can help you choose the right configuration that aligns with your work needs as well as your budget needs.

You can do all the above work of calculating and weighing options, but your efforts can ruined if the person operating the plasma cutter hasn’t had proper training.

Inexperienced or untrained operators can inadvertently escalate costs through minor errors that lead to more material waste, higher maintenance expenses, downtime, and just overall labor costs. Common issues include poor technique that might cause more wear on torch consumables/cartridges, or cause damage to the metal being worked on. This might necessitate additional or unnecessary finishing work, such as grinding, which can add up quick.
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But one of the greatest things about the Powermax systems is their user friendliness! They’re simple enough to operate that even novices can get professional-grade results fast! Of course, learning the correct techniques is essential for peak performance and safety. Which is why it is also great that Hypertherm provides a wealth of training resources- from face-to-face workshops to online courses and tutorials via the Hypertherm Cutting Institute. Having accessible training not only minimizes operator mistakes but also ensures the accuracy of your total cost of ownership calculations.

TIG welding stands out for its precision, versatility, and the clean, high-quality welds it produces. At the heart of this welding method is the tungsten electrode, an unassuming yet pivotal component that influences the outcome of your weld. The focus of this article is not just on the role of tungsten in TIG welding, but more specifically, on the critical aspect of sharpening tungsten electrodes. The way these electrodes are sharpened can dramatically affect welding performance, making it an area where attention to detail pays off.

Your electrodes should be ground longitudinally and concentrically to a specific included angle. You also must consider the tip/flat preparation. The included angle or taper at which a tungsten electrode is sharpened to affects its welding capabilities. Different angles produce different arcs and provide differing weld penetration. Welders should initially refer to the recommendations provided by the welding equipment manufacturer. However, running your own tests beforehand is what makes a good welder into a great welder.

In general, blunter electrodes that have a larger included angle last longer, have better penetration, and can handle higher amperages without eroding. They also provide a narrower arc shape. While sharper electrodes with smaller included angles provide a larger and more consistent arc.

Larger tungsten diameters and higher currents are normally paired with larger tapers in the 25° to 45° included angle range- this allows them to last longer with a more stable arc. More pointed tips in the 10° to 25° included angle range can be used for lower currents. 

The choice of angle depends on the welding task at hand and can greatly influence the ease and quality of the welding process. Here are some examples:

A 25° included angle creates a stable and controlled arc, making it perfect for welding thin materials such as sheet metal. Although it might not be the best option for fill passes, particularly when using lay-wire techniques, it's an excellent choice for beginner TIG welders looking to improve their arc and puddle control.

A 35° included angle offers a highly versatile arc that's appropriate for a wide range of welding tasks. It ensures a consistent arc that produces ideal penetration, surpassing the performance of longer tapered grinds in terms of both control and depth.

A 45° included angle takes advantage of the powerful penetrating arc. This blunter grind angle provides a sharp, deeply penetrating arc that may have some initial arc wander. But, it guarantees strong weld penetration and a narrow puddle. Great for projects involving aluminum and stainless steel, particularly where structural integrity is top priority, and bead size matters.

The finish quality on the tungsten electrode's tip also affects the welding process. A finer grind improves welding properties and extends electrode life. Electrodes ground too coarsely can lead to arc instability. 

A crucial factor in electrode grinding is ensuring the grind is longitudinal. This is because the grain's molecular structure in tungsten electrodes runs lengthwise, and grinding across this grain disrupts the flow of electrons, causing the arc to start prematurely, spread out, and potentially wander. This not only overheats the electrode but also shortens its lifespan. Longitudinal grinding promotes a straight, stable, and focused arc.
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What you use to grind your electrode is also important. A diamond grinding wheel used exclusively for tungsten is important to avoid contamination that could affect the weld's purity. This setup allows for longitudinal grinding, minimal tolerance variations, and prevents contamination. It's also crucial to cut off the contaminated part of an electrode. Simply grinding a contaminated tip can spread the contamination further. Since tungsten is hard, a diamond cutting wheel provides precise, clean cuts.

Common incorrect methods include manual breaking, twisting with pliers, notching and breaking, or using a hammer. These can compromise safety and weld quality, risking splintering of the tungsten and causing arc instability or personal injury. The right cutting tool, designed for tungsten's hardness and brittleness, ensures clean, smooth cuts without fractures, enhancing safety and precision!

Regular maintenance of tungsten electrodes includes recognizing signs of wear and the need for re-sharpening or replacement. A properly maintained electrode ensures consistent welding quality, minimizes downtime, while preventing material waste. Inspect electrodes for wear, contamination, or damage before each use. After significant use or if contamination occurs, re-sharpen the electrode. And lastly, be sure to store your electrodes in a clean, dry place to prevent contamination!

Understanding the types of tungsten electrodes, the importance of their preparation, and the effects of different sharpening angles allows welders to improve their welding quality and efficiency. Best practices = best welds! In the world of TIG welding, the angle, tip preparation, and condition of your tungsten can make all the difference. Prioritize tungsten prep and you'll be sure to see improvements in your welds!

Ever been working on project when you run into the need to do some metal cutting? Maybe you already own an old oxy-acetylene torch that you haven’t used in a while and your plan was to dig that out for the job. But when it comes time to make your cut, you might experience poor quality cuts with a rough edge, excessive slag or dross formation on the underside of the cut. Or possibly warped metal from the heat input, leaving you with an undesirable finished product. 

Well, what if there was a faster, easier, option? Here comes plasma cutting!

Choosing the right welding screen or curtain is crucial for worker safety. Harmful UV and blue light radiation can happen during welding so you need proper protection. But how do you choose what's right for you? Let’s dive into some essential tips on navigating the size, color, and safety aspects of welding screens!

Welding screens, typically made of semitransparent vinyl affixed to a frame, offer portable and flexible solution. They can be configured in three- or four-sided setups, making an enclosed box for your welding setup! Screens like this come in many sizes and shapes and can often be found on construction sites and mobile welding operations because of their portability. They’re also used in welding shops and manufacturing facilities that need flexible protection.

Welding curtains are commonly hung from a frame or ceiling and are generally more stationary set ups. There are lots of varieties but the vinyl grommeted curtain is most common- fastened to a frame, fence, or other structures, using the grommeted holes along the material's edges. Another common type is the welding strip curtain- composed of overlapping PVC strips that can be semi-permanently secured to a structure or suspended from the ceiling. Curtains are generally used for permanent welding booths!

Understanding the differences helps in selecting the right option based on mobility and usage! Another factor to consider when selecting a welding screen is size. Too small of a screen may compromise protection, while too large screens can be difficult to maneuver.  

​As for material, most welding screens and curtains are made of vinyl (PVC) or polycarbonate. A benefit of vinyl is that it provides safety while being comparatively affordable- it's also scratch resistant and easy to clean making maintenance a breeze.  Plus, for screens that requiring frequent relocation, vinyl offers a lightweight and flexible solution!

It’s important to look for welding screens that have been tested and certified to meet safety standards. OSHA and ANSI safety standards will ensure proper protection against UV and blue light radiation. They also must pass specific anti-flammability tests. To be compliant with this standard, screen and curtain makers must check the levels of optical and flame protection at an independent laboratory. After it’s been certified, they mark the screen or curtain with AWS F2.3M:2019, the manufacturer’s name, and the date of manufacture. Making sure your screen or curtain is AWS F2.3-compliant can help with safety and accident prevention.

Choosing the right color for a welding screen is vital for visibility and eye strain reduction. It’s important to consider your welding application and the environment you’ll be welding in before making a choice. Welding screens and curtains have different safety grades. Screens are categorized into light (L), medium (M), dark (D), and extra dark (E