Guide to Reducing Welding Costs For Machining Parts
As everyone knows, the welding process is a cost-effective process. However, there are a number of factors that can either raise or lower the cost-effectiveness of your project significantly. The factors range from the use of consumables to operational efficiency.
Three Processes to Welding Manufacturing Methods
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Over Welding
Over welding is the use of a larger weld than it needs to be. This commonly happens with inexperienced welders. Over welds occur when there is no fillet gauge or specified weld size design. Also, when the welder desires to create a big weld just to play it safe. Over welding causes a strain on resources such as more labor, arc time, filler metal, and shield gas. It thus raises costs. Also, bigger welds distort the part more due to more heat input. Excessive convexity increases the chance of the weld failing because of fatigue. Thus to save resources, we ensure the use of fillet weld gauge and avoid reinforcing grove joints excessively. Having a change in wire diameter also avoids the occurrence of over welding.
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Right Welding Process
The selection of the right welding process is important when considering aesthetics. It is important to consider a few factors before picking a welding technique. Welding is a better pick than metal inert gas (MIG) welding in terms of precision. However, the former needs more skill. When aesthetics is the main factor considered, TIG is the better option than MIG. It is because the latter causes more time to be spent on finishing later on. Also to ensure less consumption of resources than necessary, there is a need to revise all considerations. The wrong process results in rejects production.
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Weld Automation
The weld automation is very good mothed to have reducing welding cost. The use of weld automation makes welding more cost-effective, safer, more productive, and faster. It involves the use of equipment that either partially or fully automates the welding process. Human operators, despite their level of skill, are prone to fatigue and making errors during welding-related activities. Factors such as handling welding equipment, positioning, and safety concerns affect welding productivity.
The options for welding automation greatly affect productivity and cost. However, there are different levels of applying automation in welding. Hard automation, for instance, involves the use of weld manipulators, turning rolls, and weld positioners to keep weldments in place. On the other hand, fully automated setups carry out welding using robotic arms. This type of welding is known as robotic welding.
How To Keep Better Welding Equipment For Cost Reduction?
- Welding Equipment Maintenance
Proper maintenance of welding equipment results in great cost-saving levels and productivity. Faulty equipment results in more consumption of resources and the generation of more waste. Having faulty appliances and frayed cables does lead to wire feeding problems, voltage losses, and irregular arcs. Also, bad gas systems result in gas leakage. These examples contribute to inefficiency in welding operations. It also results in the production of poor quality welds. This compromises weld safety and leads to more rejects production. Therefore, it is important to invest in a company that has effective maintenance programs. This will overlay reduce welding costs in the long run.
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Use of Consumables
Consumables in welding include filler metals, shielding gas, back bars, and anti-splatter compounds. These materials do have a noteworthy effect on the total reducing welding costs. Thus, the proper use of these consumables results in keeping costs low. Specific consumables should only be utilized when absolutely necessary. We regularly check gas delivery systems for any leaks then seal them off. Also, the attachment of surge guards and surge turbines to welding guns ends that measures pressure reduction and gas surge, respectively.
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Joints and Gaps Preparation
Before the welding process begins, there is a need to prepare joints and gaps properly. This results in a problem-free welding process. First, the welding operators have to clean the base materials’ surfaces. This helps in preventing contaminants, like oil and dirt, from being within the weld puddle. Next, is ensuring a setup of the right fit-up with no excessive gaps. Poor fit-ups have many negative effects. For example, there is a chance of burn through or distortion occurring, thus compromising weld strength. Additionally, it leads to over welding. This occurs as there is a need to achieve an equal load-bearing capacity with increased weld sizes. For instance, we require a ¼” fillet for a joint with no gap. However, for a gap of 1/8” in a similar joint, it needs a fillet of 3/8” in size to achieve a similar strength. This translates to a 130% increase in filler amount consumed, these machining details will definitely have reducing welding costs for your projects.
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Reworks and Rejects
During welding, it is important to minimize rejects and reworks. We waste time used, labor, filler material, and shielding gas when a reject occurs. Also, reworks result in the wastage of labor, resources, and time. Thus, at Creatingway we ensure we put in great skill and efficiency to eliminate the occurrence of reworks and rejects. Contact Creatingway now for your welding needs.
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