Using more competent welding processes and technologies could help contractors complete jobs faster and compete for more bids.
FREMONT, CA: Consider new technologies. The construction industry outlook remains vital in many sectors. Still, a continued shortage of skilled labor is a key challenge on many job sites — one that may obstruct contractors and structural steel erectors from finishing projects on time or even competing for some projects.
There are two means to address the lack of skilled welders: Recruit and train more welders in the trade or be more efficient with the workforce already on the job site.
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A transition to wire welding processes is one lever contractors can pull to improve productivity and efficiency. Due partly to the significantly higher deposition rates and travel speeds wire processes can deliver, more companies are moving from stick welding to wiring welding on construction job sites. These gains can be realized while meeting high weld quality requirements and improving jobsite safety.
Following key best practices for wire welding in the field and utilizing the right technologies can aid improve efficiency and reducing weld defects — so projects can be done faster.
Tip No. 1: Make adjustments remotely
On structural jobsites, welders may require common adjustments to welding parameters to get better outcomes. However, when the welder must leave the weld joint and walk to the power source to make changes — possibly up or down ladders or several flights of scaffolding in the process — these trips can add up to several hours lost every day while also growing the risk of injury.
Welding technology lets welders make parameter adjustments at the weld joint with a wire feeder or stick/TIG remote, following more arc-on time, higher quality welds, and a safer jobsite. ArcReach® technology from Miller Electric Mfg.
LLC enables operators to make adjustments at the weld joint using the wire feeder or the remote without needing a control cord, so they don't have to walk to the power source to make changes. On some jobsites, this trip could span 200 to 300 feet or more across a cluttered jobsite, perhaps down ladders or flights of stairs. Since the ability to make fast and easy adjustments at the weld joint with remote control technology eliminates the long walk to the power source, there is no need for welders to make do with less-than-optimal settings. Instead, this helps them produce high-quality welds.
Tip No. 2: Eradicate cable length voltage drops
One general issue on the jobsite is confronting the voltage drop in weld cables. Voltage drops happen because of resistance in the welding circuit, caused by distance, several connections, and corroded or dirty connections.
Usually, the longer the leads and the more connection points, the more resistance in the weld cable. The following voltage drop can lead to arc performance issues unless operators compensate for the fall, leading to potential weld quality issues.
In traditional equipment, operators must manually adapt for this by setting the voltage higher than requisite at the power source to guarantee they get the voltage they want at the feeder. This is frequently a guessing game, needing welders to set a certain voltage, weld for a bit, then either radio another worker or return to the power source to adjust voltage again before walking back to weld more. This may happen numerous times before the right level is dialed in.
This wastes time and can raise questions from the quality control inspector about why the voltage at the power source is higher than the weld procedure allows. This time and hassle can be eliminated.
To optimize arc performance and quality on the jobsite, it's also important to use the proper size cables, ensure all connections are tight and free of corrosion, and keep weld cables straight and uncoiled during welding.
Tip No. 3: Deal with dirty power
What'sWhat's referred to as "dirty power" can happen when inconsistent primary power is fed to a welding machine. In addition, portable generators can be a source of dirty energy on the jobsite since they may not provide a smooth electrical wave.
Generator technology has improved, making dirty power a less common problem. However, since many jobsites still use older, legacy generators, it's important to look for welding solutions to protect against dirty power.
Be conscious that transformer-based equipment often requires greater power consumption on a jobsite. Newer welding power source technologies can give much greater power efficiency and save on operational costs. With some larger engine-driven welder/generators, it's possible to power up to six smaller welders simultaneously.
Wire feeding issues can stem from several factors. Knowing the reason will aid in determining the best course of action to fix the problem.
Choose the right drive roll: When choosing the drive roll size and type, consider the size and type of wire. The tubular wire is softer and requires a knurled drive roll, with teeth to grab the wire and help push it through.
Nevertheless, knurled drive rolls shouldn't be used with solid wire because the teeth will induce shavings to break off, which can clog the liner. Employ a smooth, V-groove drive roll with solid wire. Swapping the drive roll to match the wire helps promote consistent wire feeding and reduces maintenance on the MIG gun.
Set proper drive roll tension: Setting the tight pressure can deform the wire. Too little stress can cause wire slippage. To set appropriate tension, release the tension on the drive rolls, then increase tension while feeding the wire into a wood block. Continue increasing pressure one half-turn past wire slippage. It's vital to properly set the tension each time the drive roll changes.
Redesigned inlet guide: Feeder technology has enhanced over the years, resulting in smoother and more consistent wire feeding. For improved wire feeder performance, Miller wire feeders use an inlet guide to reduce wire drag from the spool for more consistent wire feeding into the drive rolls.
Trim the liners: Arc birdnesting, instability, and burnback can outcome from liners that are kinked, worn, the wrong size, or partially plugged. Blow compressed air over the liners to remove dirt and debris and improve feeding performance. Immediately replace the liner if a blockage is found, and always trim the liner per the manufacturer's recommendation.
Tip No. 5: Concentrate on safety
Several welding technologies, including the capability to control parameters at the weld joint provided by ArcReach technology, help improve jobsite safety.
Technology that lower the number of trips welders must make on a crowded jobsite to change parameters reduces slip, travel, and fall hazards.
First of all, preventing jobsite accidents impacts employee safety and well-being. Improving security can also have a financial effect by decreasing the cost of worker downtime, insurance, or workers' compensation payments. Jobsite safety records may also be stated in some contract bidding; contractors with poor records can have a harder time winning bids.
