While one of the most widely used and accessible methods of welding, gas metal arc welding (GMAW) is actually a balancing act of many important variables that greatly affect the quality of the weld. Commonly known as MIG welding (short for “metal inert gas”), this method utilizes a consumable metal as an electrode like shielded metal arc welding in the form of a wire. The wire is fed semi-automatically or automatically through a gun that supplies the shielding gas necessary for protecting the weld pool from exposure to the atmosphere.
Chemical heat exchangers, dealing with volatile chemicals at high temperatures, are prone to corrosion. Fortunately, tantalum is one of the most corrosion resistant metals on earth. AT&F Advanced Metals has experience with many specialty metals, including tantalum, and have manufactured many tantalum heat exchangers, lined pressure vessels, and other specialty application components that make use of the metal’s properties.
TIG Welding: Precision and Preparation
When a welding job requires precision, the obvious method to use is TIG welding. Gas tungsten arc welding (GTAW) is a welding method using tungsten as an electrode and argon or helium gas as a shielding agent. When GTAW was first introduced in 1941, it used exclusively helium as the shielding gas. This gave it its original name: Heli arc welding. It is now referred to as tungsten inert gas welding, or TIG for short. It is a slow and difficult method to master, but a trained welder can use TIG welding to produce very high quality welds. But what makes TIG welding so precision oriented? And why do TIG welders have to feed the wire by hand?
From the Floor: Weld Institute Expansion
AT&F is an industry leader in welding capabilities, with in-house robotic welding, and a Weld Institute that teaches students the fundamentals of welding—as well as advanced techniques—courtesy of our highly skilled welding engineers. Our Weld Institute, formed in (2015), is currently undergoing repositioning and expansion to accommodate larger classes and cover more welding types.
Safety When Welding
Welding, like any job in a fabricating facility, comes with risks. Some risks are inherent to the craft, and some are factors of the environment, but all risks can be assessed and mitigated, if not completely eliminated, by following procedures. Safety has been a pillar for AT&F since our creation in 1940. The priorities that drive our business are “Safety, Quality, and Productivity,” in that order, and welding is no exception. Our in-house Weld Institute starts every course with an overview of safety to set the standard as soon as our welders begin learning. With 90% of all injuries in the workplace occurring due to operator error, preventing accidents like these begins with proper procedures.
Press Release: AT&F Wisconsin Upgrades Facility
AT&F is pleased to announce recent upgrades to our Wisconsin facility, including a brand new plasma and oxy-fuel cutting table with a 5-axis beveling head, and improvements to a large capacity boring bar. In addition to the equipment upgrades, AT&F Wisconsin is pleased to announce the addition of a Certified Weld Inspector (CWI) to further enhance the welding quality and provide a valuable resource for proper procedures and training. These upgrades are part of AT&F’s continuous improvement initiative and bolster the Wisconsin facility’s capabilities for a competitive market.
The History of Welding
For millennia, metals have been manipulated to man’s wants and needs. But from primitive hammers and anvils to high-tech robotic lasers, man’s methods of manipulation have changed and evolved drastically over time. The impact of advancements in welding has built skyscrapers, automobiles, and even nuclear reactors, but the genesis of welding looked nothing like the advanced technology we have at our disp
osal today. Paving the way for modern structures and safer machines, welding plays a crucial role in our daily lives.
How Welding Works
Welding is a ubiquitous method of metalworking that joins two pieces of metal together to form a strong bond. But what exactly happens when the two metals join together? By definition, welding joins two pieces of metal by fusion. In order to properly fuse together, the base metal must melt and flow together. Older welding methods would employ an oxyfuel blowtorch to heat pieces of metal until the base metals reached melting temperature, but newer methods now use an electric arc to generate the heat necessary to melt the metal. The arc is created when an electric charge is passed from an electrode to the workpieces. The electrode is usually consumable and charged either negatively or positively depending on the desired character of the weld. A proper weld often creates a bond between workpieces that is stronger than the original strength of the workpieces themselves.
Fabricating vs Forging
Metalworking is not limited to fabricating. Forging is another form by which metal is manipulated. Both forging and fabricating have their strengths and weaknesses, and one method may be better suited for your needs than the other. Let’s break down the differences between the two methods.
From the Floor: Depressed Transition Pieces
AT&F is big in the railcar industry. For train cars to maximize the load size, cars will be fitted with s-shaped plates that drop the load between the wheels. The depressed railcar transition pieces are made from 2 ½ inch A514 steel, a very strong grade of steel that is difficult to form. AT&F proved its ability to form the heavy pieces to tight tolerances and added value in keeping the job domestic. The strength of the part is maximized due to the properties of arches, which lends itself to bigger loads. These larger loads benefit from the depressed seating in that height is shaved off the load, allowing for heavy loaded trains to easily pass through tunnels. AT&F takes pride in pushing the limits of size and scale and delivering quality parts where other fabricators fall short.