4 Common welding challenges and how to overcome them

Everyday, welders, manufacturers, maintenance teams among others, face many welding challenges. With proper knowledge and having the best and latest welding equipment can help in avoiding most of the errors and overcoming the welding challenges. In this article, we present you four common welding challenges and ways to overcome them.

4 Common welding challenges and how to overcome them

1. Welder Safety: Safety is the first and foremost challenge welders will have to address in order to avoid all the consequential issues that may arise. Therefore, wearing Auto-darkening welding helmets, gloves, and wearing the PPE (Personal Protective Equipment) of right quality and being fire-resistant.
2. Weld Defect: Porosity in weld bead is one of the visible weld defects that welders face on a day-to-day basis during GMAW (Gas metal arc welding) process. For example, porosity formation in Zinc Coating (GI coated sheets such as galvanize coatings on steels) is generally stripped from the area to be fusion welded (usually by thorough wire brushing), including the immediate surrounding area of any heat-affected zone (HAZ). Zinc has a low melting point and a boiling point, and a high vapor pressure, all of which leads to it forming Zinc vapor in electric arcs. Due to this, porosity is not only the result but the more serious problem is toxicity to the welder. Latest technology like Fronius patented CMT cold metal transfer will aid the welder to overcome this challenge.
3. Selection of Welding Parameters: Selection of parameters for various base materials is the biggest challenge welder face professionally. For example, in the automotive industry, due to introduction of light weighting concepts, the new generation steels are being used. Welding of these steels will be easily possible by utilising the advanced intelligent revolution inverters and get acquainted with the research on different alloys which enable the welders to arrive at the parameters easily by selection of relevant synergic lines available with the intelligent inverters.
4. Identifying the base material: Everyday there are new base materials that are invented and discovered. Also, new alloys are being developed. Each base material requires a different set of parameters and a different kind of power source. Non-ferrous metals like alloys of aluminum, magnesium are difficult to identify and join. This is because of their affinity towards oxygen and they have a layer of metal oxide which has higher melting points. Fronius has developed GMAW process to join these alloys with a consistent quality.

Related Article: Evolving welding technology and improved training processes – Read more: https://nationalskillsnetwork.in/oldsite/expert-speak-evolving-welding-technology-and-improved-training-processes/

Right from helping people in planning, development and in carrying out everyday welding, Fronius has been providing expert opinions and suggestions to many welders over the years. It has also been providing right welding solutions saving time and money, thus giving organisations a competitive advantage over their peers. Latest equipment along with right use of technology and data will help in solving some of the most difficult and complex problems that welders face on a day-to-day basis.