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An introduction to friction stir weldingBy Jeff Defalco, Contributing WriterSeptember 15, 2009A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects. Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.HistoryFriction stir welding was invented by The Welding Institute (TWI) in December 1991. TWI filed successfully for patents in Europe, the U.S., Japan, and Australia. TWI then established TWI Group-Sponsored Project 5651,”Development of the New Friction Stir Technique for Welding Aluminum,” in 1992 to further study this technique.The development project was conducted in three phases. Phase I proved FSW to be a realistic and practical welding technique, while at the same time addressing the welding of 6000 series aluminum alloys. Phase II successfully examined the welding of aerospace and ship aluminum alloys, 2000 and 5000 series, respectively. Process parameter tolerances, metallurgical characteristics, and mechanical properties for these materials were established. Phase III developed pertinent data for further industrialization of FSW.Since its invention, the process has received world-wide attention, and today FSW is used in research and production in many sectors, including aerospace, automotive, railway, shipbuilding, electronic housings, coolers, heat exchangers, and nuclear waste containers.
“If you can’t stand the heat, get out of the kitchen.”
This expression makes absolutely no sense if you’re in the profession of welding.
#1: If you can’t stand the heat, why the heck are you a welder?
#2: There is no kitchen. What kitchen? If you’re welding in a kitchen, get out of that kitchen. Right now! There are gas mains!
#3: If you can stand the heat, and you’re not in a kitchen, then why would you move? Stay right there!
In fact, let’s add some more heat. Let’s add some… friction.
That’s right, you heard me. Friction, as in friction stir welding. FSW. It’s all the rage in… in…
Just read…
An introduction to friction stir welding
By Jeff Defalco, Contributing Writer
September 15, 2009A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminum alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material.
Friction stir welding (FSW) is a relatively new joining process that has been used for high production since 1996. Because melting does not occur and joining takes place below the melting temperature of the material, a high-quality weld is created. This characteristic greatly reduces the ill effects of high heat input, including distortion, and eliminates solidification defects.
Friction stir welding also is highly efficient, produces no fumes, and uses no filler material, which make this process environmentally friendly.
Welding can be punny. It can. And just to prove it to you all, I have my handy-dandy-back-pocket-article right here, and it’s all about stud welding. Just take a look at that title. Yeah, I told you. Punny.
Small studs, big impact
Change in stud welding material saves power plant millions
By Chris Hsu
September 1, 2009
Stud welding, an often-overlooked process, can have a significant effect on the life-cycle cost of a product.
Stud welding can be performed with a hand tool that is brought to the material. Photo courtesy of Nelson Stud Welding.
In coal-fired power plants, so much relies on the little things. Smooth, cylindrical studs 3/8 inch in diameter by ¾ in. long are placed in furnaces operating at 1,600 degrees F or more. The studs transfer heat from the hot side (the furnace) into the boiler tube.
A refractory coating, which protects the tubes from erosion, is applied over the studs. As the stud wears, so does the refractory coating. At some point the studs become so short that the furnace has to be shut down, the studs rewelded, and the refractory coating reapplied.
For decades plants have used 430 stainless steel studs, a material that has to be replaced about every 12 months. This can be an expensive endeavor, especially if unplanned.
That article was “such a stud”. Just kidding – I don’t think that was grammatically correct. So, what do you think – stud welding – stud or a dud?
Interested in saving money while you’re welding this autumn? Check out this article by Welding Magazine — it lists ten simple ways that you stay thrifty, and that’s just when you’re using your MIG gun!
10 Money-Saving Tips for Semi-Automatic MIG Guns
By DAVID BELLAMY | Jul 1, 2009 12:00 PM
Your welding operation, just like any other portion of your business, offers opportunities to conserve resources.
The economy continues to challenge all of us, and it seems everyone is watching his or her finances (at home and on the job) and looking for innovative ways to save money. Your welding operation, just like any other portion of your business, offers opportunities to conserve resources. Consider these 10 money-saving tips for MIG gun care and maintenance, and don’t be surprised to discover you will improve your welding performance in the effort.
TIP #1: PROTECT YOUR ASSETS
Keep your nozzles, retaining heads (diffusers) and contact tips in the original shipment package until you are ready to use them. This prevents scratches and/or dents where spatter can accumulate and will make them last longer. It also prevents dirt, oil or other debris from adhering to the consumables and inadvertently entering the weld puddle.
What are you doing this fall to save cash? Share your best ideas with the rest of us!
Plasma Arc Welding (PAW) and Plasma Arc Cutting (PAC) are two processes that are pretty amazing. Plasma refers to the physical state of gas after it has been exposed to extremely high temperatures. This ionized stream of gas generates a column of heat that is used for welding or cutting metals.
You won’t find a lot PAW applications in a backyard weldshop, but Plasma Cutters are pretty common….
If you already know all about plasma cutting, then this article is not for you. This article is for newbies, for people like, well, I’ll just say it — for people like me. But now that I’ve read the article, I think I might be ready to move on up in the world… you know, to articles like these –>
Plasma cutting and how it works
By Kent Swart, Contributing Writer
August 11, 2009What is plasma cutting, and when is it your best metal cutting option? What information do you need to choose the right plasma system? This article answers these questions and more about plasma cutting.
The basic technology for plasma cutting has been around for decades. Researchers and engineers remain focused on increasing cut speed, improving cut quality, and extending consumable life, while making systems smaller and more powerful.
What Is Plasma Cutting?
Once a gas is heated to an extremely high temperature and ionized, it becomes electrically conductive and is considered to be plasma. Plasma arc cutting and gouging processes use plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the arc’s heat and then blown away.
First off is the general information – FABTECH’s main website with the who, what, where, when, why, and a magical little button that you push to attend.
FABTECH International & AWS Welding Show including METALFORM
The FABTECH International & AWS Welding Show now including METALFORM hits McCormick Place in Chicago, Nov. 15 – 18, 2009. The MEGA event anticipates hosting over 1,000 exhibitors, drawing an expected 35,000 attendees and featuring thousands of live equipment demonstrations throughout pavilions dedicated to metal forming, fabricating, tube and pipe, stamping, lasers, thermal spray and welding.
Secondly, Miller is going to be there (booth #34701 – write it down) and they will be showing some fabulous new products, so don’t forget your cameras.
Miller to Unveil Latest Welding, Safety and Fume Extraction Products at the 2009 FABTECH International & AWS Welding Show
Visit booth #34071 to see:
AlumaFeed™ Aluminum Fabrication System
FILTAIR™ MWX-D Mobile Fume Extractor
Miller’s Arc Armor™ PAPR (Powered Air Purifying Respirator)
PipeWorx™ Welding System
Trailblazer® 302 Air Pak™Live arc demonstrations
APPLETON, Wis., August 13, 2009—Miller Electric Mfg. Co. will present its latest arc welding, welding safety and fume extraction products as well as live arc demonstrations in booth #34071 at the 2009 FABTECH International & AWS Welding show, November 15 to 18 at McCormick Place in Chicago. New products include the AlumaFeed™ Aluminum Fabrication System, FILTAIR™ MWX-D Mobile Fume Extractor, Miller’s Arc Armor™ PAPR, PipeWorx™ Welding System and Trailblazer® 302 Air Pak™. Additional products will be announced as show date nears.
Lastly, this is the first year that FABTECH International and AWS are partnering with METALFORM, resulting in more exhibits, more attendees (hopefully), and by and by large, a better show.
FABTECH INTERNATIONAL & AWS WELDING SHOW ANNOUNCE STRATEGIC ALLIANCE WITH METALFORM
First combined trade show will take place November 15-18, 2009, at McCormick Place, Chicago, IL
DEARBORN, Mich. – April 2, 2008 – Four industry-leading trade show organizers have formed an alliance to better serve the needs of trade show exhibitors and manufacturers in North America from the fields of fabricating, tube & pipe, welding and cutting, metalforming, and related processes. The show alliance between the three organizers of the FABTECH International & AWS Welding Show [the Society of Manufacturing Engineers (SME), the Fabricators and Manufacturers Association International (FMA) and the American Welding Society (AWS)] and the organizer of METALFORM [the Precision Metalforming Association (PMA)] will result in a combined annual exhibition.
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