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Financial Advantages of FCAW Welding for Industrial Applications

FCAW or flux cored arc welding is an excellent metal joining process for companies involved in heavy metal fabrication or repairs. This process provides the fastest metal deposited rates of any manual type of welding and best of all it required the minimum skill level from your employees. There are many cost saving advantages of FCAW that will help your company's bottom line and they are:

Fast deposit rates Minimal joint preparation Low skill level required Cost savings

FCAW has the fastest deposit rates of any manual welding process out there! One welder using the flux cored process can easily deposit two times the amount of weld as a stick welder. The deposit rates are more than twice the rate of stick welding and MIG welding. Not only are the deposit rates much higher but this type of welding can be done outdoor situations unlike MIG welding. FCAW can deposit as much as 25 pounds of filler metal in a single hour. Comparing this to MIG welding where 8 pounds of filler wire an hour is the maximum deposit rate it only makes sense to use FCAW for heavy metal welding needs.

This process is one of the very few that does not require a clean weld joint in order to produce a sound quality weld. FCAW can easily burn through mill scale, rust and some paint and at the same time it can weld ½ inch thick plate in a single pass. Most other welding processes would require multiple passes that would take more time and a clean weld joint in order to complete. This is the main reason shipyards use FCAW for the majority of their structural welding needs.

The skill level needed for FCAW is the bare minimum! Stick and MIG welding require a lot of skill compared to this process and that means employees need more training and experience compared to flux cored welding. Just about anyone can learn how to weld in just a matter of weeks compared to years for some other types of welding. This means finding welders or even retraining other staff is easier done!

Cost savings in this economy is the major focus for large and small businesses today. When comparing FCAW to other welding processes the numbers all point to flux cored welding as the winner. Looking at the deposit rate alone a single welder can easily replace two or more employees. This translates to the same amount of weld without the cost of the unneeded employee's salary, insurance and administrative cost involved! Not only does this eliminate the extra payroll expenses but also opens the door to hiring less skilled labor that can be either be retrained lower skill level employees, hiring directly from welding schools or training center for a much lower hourly rate. The icing on the cake is the cost saving from the fabrication department in joint preparation. Since this process does not need a clean joint there are many hours saved in labor cost from other employees. In the end how much money can your company save by reducing the cost of payroll and how happy would your boss be with FCAW as your newly preferred welding process? Flux cored arc welding simply point to higher profit margins and a bigger bonuses.

Article Source: http://EzineArticles.com/6478683

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Steel welding needs lot of expertise to make a quality welding. The welding machine described in this article can do this without any hassle. All of the welding machines are budget friendly and have good customer feedback. 

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Solar Powered Auto Darkening Welding Helmets

For those less familiar with auto welding helmets, you should know that a range of welding helmets are built using fixed internal batteries, which can not be replaced, usually assisted with a solar panel. They tend to need charging in the sunlight before use and after prolonged stored periods.

The welding industry has really taken to using photovoltaic cells and technology, and has been growing in the last few years. Solar powered tech is commonly used by most brands in the market that specialise in ADF (auto darkening) welding helmets.The common misconception being of course people assume “solar powered” welding helmets have not batteries, this isnt true. they do have battery packs to power up the initial arc, and use low powered rechargeable cells powered by the PV panel.

The problem there is of course that the welding helmet isn’t ready for immediate use if you need it, which could be a pain sometimes. The other problem is that if the battery dies, the auto darkening lens wont work.

Why use Solar Powered Welding Helmets?

The most common misconception is that the solar panel is there to power the battery packs. This isn't true – your battery packs are required to power the mask or hood, and to start your arc. Once the arc is in play, typically the UV light that is gives out powers the solar panel in your welding hood, which in turn powers the electronics in the hood.

The advantage here is of course you are preserving your normal battery, while the solar cell is doing the heavy lifting, thus an economical way to use your helmet.

Additionally most solar helmets come with auto off features which can be handy if you are the forgetful sort and forget to power off your helmet.

Solar powered helmets also tend to be lighter.

The top performing ranges in the solar models are normally battery assisted and include a cell to improve the performance of the auto darkening filter. The non battery assisted models need replacing every few years, and are cheaper and lower in weight. You can check here the best budget welding helmets. 

Key things to consider when buying a solar powered welding helmet

  - Aim for a replaceable battery pack   - Try for a triple A battery as they are easy to replace and cheaper.   - If aiming for battery life, consider a Lithium battery pack.   -  Allow for charging time before welds.

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Mig welding benefits & disadvantages

MIG welding is the most commonly used of welding procedures. It is a procedure working with a spool of continuously fed wire, and may be utilised to join extended stretches of alloy.  A cable electrode is fed to some weld while inert argon gas stipulates a blanket from contamination.  The method induces an electrical arc to form between the electrode as well as the alloys, which moves the metals and also induces them to combine together.

When you perform welding tasks with a mig welder machine, you will get the following benefits:

1) Higher welding Rates 

2) Greater deposition rates

3) Less post welding cleaning (e.g. no slag to processor off weld)

4) Better weld pool visibility

5) No stub wind losses or wasted man hours caused by shifting electrodes

6) Low ability factor needed to function M.I.G / M.A.G.S welding torch

7) Positional welding offers no problems compared to other procedures. 

 8) The process is easily automated

9) No fluxes required Generally 

10) Ultra low hydrogen process

Disadvantages of mig welding:

1) Sensible to rust and humidity

2) In some situation only outdoor welding is possible

3) Higher maintenance costs due to extra electronic parts

4) High Radiation effect

== also see the comparison between mig & tig welding.

#mig welding #mig welder #welding #mig welding machine #multiprocess welder