Reducing welding costs: 5 effective methods for companies - Codinter

They are welding equipment that uses an electronic board or chip instead of a transformer to convert the alternating current into direct current.

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The operating principle of the inverter for welding is that the frequency of 50-60 Hz of the alternating current that comes from the electrical network increases considerably, between 20,000 Hz and 50,000 Hz.

A higher frequency implies the use of a smaller transformer, which allows the manufacture of smaller and lighter energy sources.

Due to the change in their internal components, inverting welding machines are, on average, 3 times lighter and smaller than traditional machines. This allows the operators to work in heights or places of difficult access.

Since they provide continuous current, inverting welding machines can use any type of electrodes. They can be used for all types of arc welding. In addition, there are single-phase and three-phase models.

Good penetration and stability of the arch is guaranteed with the use of inverting welding machines. This is due to the continuous control of the properties of the arc, even when the voltage is unstable or weak.

They also consume less energy than their peers with transformer-only technology. Lower amount of energy represents savings in operating costs.

The best welds come from the pure contact of clean metal with metal. Any foreign material in the welding area can cause imperfections in the weld. Depending on the material, the size and shape of the piece, you can consider some mechanical techniques such as:

The use of the polisher or emery: An angular polisher with an abrasive or wire disc (pleasant) is ideal for preparing steel for MIG or TIG welding. It is not recommended in very thin sheets since it can compromise the resistance of metals.

Orbital polisher: This type of polishers can be useful to clean smooth or flat pieces.

The use of sandpaper or wire brush: It is a manual operation that works very well in cleaning steel parts for MIG and TIG welding or stainless steel, but it can take much longer and does not always eliminate all the oxides or impurities in the metal.

Abrasive blasting: If the metal to be welded is very oxidized and is not suitable for sanding or removing with a polishing machine, another option for preparing the metal is to do it with abrasive blasting.

Traditionally sand has been used, but today there are other materials available.

There are many activities that are necessary and some are more difficult to take into account, but they affect the cost of welding. We can see some before welding and when welding.

Before welding

Preparation of the solder joint: This may include placing a bevel on a plate or simply cleaning the joint to free it from scale, rust, oil or other contaminants.

Assembly: This is to assemble all the parts in an accessory or simply take them to a welding station where the welder can easily take all the necessary components.

Positioning of the piece: In some cases, we can not locate the piece, but when we can, we will move it to weld it more easily.

When welding

Change the filler metal and / or the shielding gas: The wire spools, the bar electrodes and the protection gas bottles when they are finished. We need to account for this time of change.

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Breaks and meetings: most companies allow breaks. This can be as little as a 10-minute break in the morning and another 10-minute break in the afternoon. This may also include time for production and safety meetings.

Cleaning: The cleaning that must be done at the end of the day, between shifts, or even between the assembly of each product.

Move the assembly once completed: Once the assembly is completely welded, it must move to another place.

Time for post-welding heat treatment: If necessary, the time for heat treatment after welding should be taken into account.

As can be seen, there are many necessary activities without welding. Some of these can not be eliminated.

Tacking can be eliminated with elaborate accessories. The change of the protection gas bottle can be eliminated by the use of a bulk gas supply system. However, in general all these activities will always be present.

Air vs. water-cooled MIG guns and TIG torches

Torch and cable cooling play an important role in gas metal arc welding (MIG) or gas tungsten arc welding (TIG), and there are two cooling methods: air- or water-cooled systems. Cooling prevents the power cable, torch or gun and consumables from overheating. For MIG and TIG welding, you need to consider similar factors and examine the following variables before choosing a system: cost, worksite location, amperage requirements, torch weight and operator comfort. 

Water-and air-cooled torch basics

Air-cooled torches use the ambient air and shielding gas to dissipate excess heat. In addition, the power cable on an air-cooled torch contains more copper than the cable on a water-cooled torch to help prevent the cable insulation from melting or possibly burning. As a result, air-cooled torch cables are heavier and less flexible compared to water-cooled torch cables. However, air-cooled systems do not require an independent radiator cooling system and extra hoses that are associated with water-cooled systems. The simpler design of air-cooled systems make them easier to operate, assemble, maintain and transport.

Both air-cooled MIG guns and TIG torches are available in a variety of amperages for a multitude of applications. Air-cooled TIG torches are popular for applications equal to or less than 200 amps, but you can also find air-cooled TIG torches in 50- and 250-amp models. Air-cooled MIG guns are available in a wide range of amperages, between 150 and 600 amps.

The alternative to an air-cooled system is a water-cooled system. Water-cooled TIG torches or MIG guns require a radiator cooling system which circulates water through the head of the torch or gun and back over the power cable to dissipate heat from the torch or gun. However, water-cooled torch and gun cables are lighter and more flexible because the cable requires less copper compared to air-cooled systems.

Water-cooled MIG guns are typically available in 300- through 600-amp models, while water-cooled TIG torches are usually rated between 250 and 500 amps. Now that you know your options, review these factors to select the right system. 

Cost

Cost is a major factor you should consider when deciding to purchase an air- or water-cooled TIG or MIG torch. Water-cooled torches and guns require a higher initial investment because you need a separate radiator cooling system in addition to the power source. Water-cooled TIG torches and MIG guns also require higher operating and maintenance costs. You must use specially treated coolant solution in the radiator cooling system rather than tap water, which could cause algae growth or scale (mineral buildup) on the internal torch surfaces and cable assembly. In addition, water leaks from hoses and the torch neck or heads may occur, which require immediate repair in order to prevent weld defects.

However, you may save money on consumable costs with a water-cooled system. Consumables typically last longer on water-cooled MIG guns and TIG torches because the radiator cooling system allows the tip, nozzle and/or diffusers to run cooler than with an air-cooled torch. This means less frequent consumable changeovers.

Operator comfort

Depending on your needs, the higher cost of a water-cooled MIG gun or TIG torch may be a viable investment. The flexible cable, lighter weight and smaller size of a water-cooled system provides more operator comfort. For example, the average 250-amp water-cooled TIG torch weighs approximately 3 ounces and measures about 6.5-inches in length, while a 150-amp air-cooled TIG torch weighs around 6 ounces and measures around 7.75-inches in length. If you are welding for an extended period of time, the greater weight of an air-cooled torch may increase operator fatigue and cause downtime.

Worksite location

When choosing air- or water-cooled MIG or TIG torches, also consider the location of the work. Is the application in the shop or in the field? Air-cooled MIG guns and TIG torches are more practical for outdoor worksites because they require fewer parts, which simplifies transport, set-up procedures and parts management.

On the other hand, water-cooled MIG guns and TIG torches are better suited to use in the shop. Water-cooled guns and torches are available in higher and lower amp options but require a separate cooling system. The water-cooling system and the extra hoses make these torches and guns less portable.

Duty cycle

Another major consideration in choosing an air- or water-cooled torch or gun is duty cycle. Duty cycle is defined as the percentage of time in a 10-minute period that the torch can be operated at a specific output without overloading. For example, to weld 16 gauge mild steel, you need at least 160 amps with 100% CO2 shielding gas. If a given torch is rated at 150 amps and you operate it at a 160-amp output, duty cycle decreases approximately 20%. Running a MIG gun or TIG torch beyond its rated output is not necessarily harder on the gun, but it may cause the torch handle and cable assembly to heat up much faster, which leads to downtime.

If the application you are working on calls for amperages higher than what the gun or torch is rated, Purchase a higher amperage gun or torch that can operate at a higher duty cycle. Both air- and water-cooled MIG guns are available up to 600 amps. On high amperage MIG applications (450 through 600 amps), the decision to use a water- or air-cooled gun depends on operator preference and cost. For TIG applications, use a water-cooled torch for jobs that are 300 amps or greater in the shop. However, for field applications, some manufacturers also offer 300-amp air-cooled TIG torches.

Contact us to discuss your requirements of Cast Iron Stick Electrodes. Our experienced sales team can help you identify the options that best suit your needs.

Choosing a MIG gun or TIG torch