Cutting & Prep | Safety | Systems & Equipment

UNDER CONSTRUCTION

MAY 2016

Arcos Industries, LLC offers over 30 high nickel alloy electrode products to handle the wide variety of critical welding applications that you face each day. Our reputation for excellent quality and superb service ensures that you can rely on Arcos to provide you with the best in bare wire, covered and tubular high nickel alloy welding electrodes.

Arcos Delivers Solutions to High Nickel Alloy Welding Challenges.

Discover for yourself how Arcos high nickel alloy electrodes can help you solve your critical welding problems. Call us today at 800-233-8460 or visit our website at www.arcos.us.

Arcos_NickelAlloy_WP__F.indd 1 1/11/16 7:55 PM

Select-Arc, Inc. has introduced Select 78, a new T-8 product that has shook up the self-shielded electrode market. Select 78 (E71T-8-H8) provides superior arc stability and low spatter emission enabling high deposition rates whether in-position or out-of-position. In contrast to other T-8 wires, Select 78 has a broad operating window that allows both experienced and apprentice welders to utilize it with ease. It offers exceptional weldability and

produces an excellent bead shape with easily removed slag.

Select 78 is expertly designed for use in critical applications such as ship and barge construction, structural steel erection and bridge fabrication.

Better yet, as Marc Young attested, “Being an ironworker means putting in long hours and laborious days under any known conditions to build North America. Select 78 allows you to put in an honest day’s work instead of a hard day’s work.”

Now discover for yourself why Select 78 sets the new standard in T-8 welding electrode technology.

Call us today at 1-800-341-5215 or visit our website at www.select-arc.com.

“Hands down, Select 78 is the best wire I’ve used in 25 years.”

Marc YoungAdvantage Steel and Construction

Ironworkers Local 3

2389 Select 78 Ad_WP_F.indd 1 11/28/15 9:52 PM

http://www.arcos.us/http://www.select-arc.com/http://www.arcos.us/http://www.arcos.us/

FORWARDSUBSCRIBE

Editor’s Letter

WELDING PRODUCTIVITYP.O. Box 516Plainsboro, N.J. 08536

SALESAlan Berg,Vice President/Salesp: 732.995.6072e: aberg@techgenmedia.com

Neil Kelly,National Sales Managerp: 610.584.5560e: nkelly@techgenmedia.com

EDITORIAL ADVISORY BOARD Larry Cherne, Information TechnologyExecutive, PraxairChris Vihnanek, Director of U.S. MetalFabrication, Praxair

EDITORIAL Abbe Miller,Vice President/Group Editorial Directorp: 847.749.6956e: amiller@techgenmedia.com

Susan Woods,Managing Editorp: 847.973.2271e: swoods@techgenmedia.com

Jimmy Myers,Senior Editorp: 503.964.7519e: jmyers@techgenmedia.com

Molly McCormack Moody,Editorial Assistantp: 262.501.6897e: mmoody@techgenmedia.com

Justin Stivers,Director of e-Mediae: jstivers@techgenmedia.com

Kylie Grossi,Office Manager/Accountinge: kgrossi@techgenmedia.com

3MAY 2016

Here in the Midwest, March can be a bit of a mixed bag. It offers up a few glimmers of hope that spring has arrived, but in reality, nobody is truly safe from winter’s brutal weather until mid-April or so.

In a surprising turn of events, however, March offered some positivity this year. According to U.S. supply executives in the most recent Manufacturing Institute for Supply Management Report on Business, economic activity in the manufacturing sector expanded in March for the first time in the last six months, while the overall economy grew for the 82nd consecutive month.

Expanding on that good news, the Purchasing Managers Index registered a 51.8 percent, which was an increase of 2.3 percent from the previous month’s reading, which was at 49.5 percent. This increase shows growth in the manufacturing industry for the first time since August 2015.

The report also indicated that the fabricated metal product segment was one of the 12 manufacturing categories reporting growth in March. That list also included furniture and related products, miscellaneous manufacturing, machinery, primary metals, and computer and electronic products.

Abbe MillerEditor-in-Chiefamiller@techgenmedia.com

For another ray of sunshine, an article published by CNBC reports the aerospace and defense industry is also booming with a “massive trade surplus of more than $100 billion per year.” The article cites a report from Deloitte, saying the sector’s gross exports grew 3.6 percent in 2015 to $143.3 billion. Since 2010, exports have grown 59 percent.

So despite the cloudy economic environment of the past several months, things are looking up for manufacturing. Add in pending contracts exclusive to the U.S. government, including the $7 billion Boeing contract for 60 F-15 and F/A-18E/F fighter jets to Qatar and Kuwait, and the forecast looks even brighter.

Just like with any weather outlook, though, the situation should still be considered wait and see. In the meantime, we’ll keep an eye on economic indicators. And, if any of our readers would like to share their stories of business growth with us, please email me at amiller@techgenmedia.com. I’m always interested in hearing more about how blue skies are ahead.

IMPROVING CONDITIONS

PRODUCTIONAngle180 Inc.p: 847.439.6226e: sarunas@angle180.com

Welding Productivity is a registered trademark of Techgen Media Group. We publish monthly. All rights reserved under the U.S., International and Pan-American Copywrite Conventions. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means such as mechanical, photocopying, electronic recording or otherwise, without the prior written permission of Techgen Media Group. Contact us at 732.995.6072 for permission. Produced in the U.S.

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DepartmentsEditor’s Letter

News & People

New Products

TIPPING

THE SCALE

UNDER

CONSTRUCTION

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12

19

25

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33

FeaturesConsumables & Filler Metals

Under constructionFive basic steps to extend the life of heavy equipment through hardfacing

Systems & Equipment

Managing informationSeven questions to ask before purchasing a welding information management solution

Robotics

Small footprint, big productivityYaskawa Motoman answers the call for compact workcells for robotic welding

Cutting & Prep

Tipping the scaleTo produce high-quality products with long life, removing weld scale prior to coating is a must

Safety

Heart healthyHow arc welders and the electromagnetic fields they produce may affect employees with pacemakers or ICDs

4MAY 2016

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YLS Next Generation Laser Ad REV 4A.ai 1 4/1/2015 11:57:08 AM

FANUC AMERICA EXPANDS OPERATIONS

Fanuc America Corp. will open four new facilities, relocate three facilities to larger offices and add three new regional training centers in 2016. The expansion includes a new manufacturing and distribution center in Pontiac, Mich.; new sales and service facilities in Seattle, Monterrey, Mexico, and Manaus, Brazil; and relocation of customer service offices from Dallas to Houston, and Mexico City to Queretaro, Mexico. The company expects to complete the expansions in North and South America by July.

DENGENSHA AMERICA ADDS TECHNICAL SERVICE ENGINEER

Dengensha America Corp. recently added Jack Zhang as technical service engineer. Zhang will be responsible for providing customer service and support assistance for new and existing resistance welding customers in the United States and Canada. He will also troubleshoot new product applications. Zhang comes to Dengensha with a background in process engineering and research.

NEWS & PEOPLE

5MAY 2016

http://www.ipgphotonics.com/http://www.fanucamerica.com/http://dengensha.com/

NEWS & PEOPLE

PMA ELECTS CHAIRMAN

The Precision Metalforming Association announced Ron Lowry, owner and president of Dayton Rogers, as the 2016 chairman of its board of directors. Dave Arndt, president of Pentaflex Inc., will serve as the board’s first vice chair, and Richard Sade, vice president of S & S Hinge Co., will serve as second vice chair and treasurer. Lowry pledged to use his PMA chairmanship to encourage manufacturers to help close the skills gap and help elected officials and the general public understand the importance of manufacturing.

ABB ROBOTICS INTRODUCES ONLINE TRAINING

ABB Robotics introduces IRC5 Operations Web Based Training, an online, interactive training course that teaches students how to operate a robot using the ABB FlexPendant and the IRC5 robot controller. The robotics training course modules are self-paced with videos, interactive simulations and practice exercises. After completing the course, participants should be able to identify personal safety solutions, robot safety features and robot system components; move and jog the robot using the joystick; interpret and respond to event messages; and modify movement instructions in a basic program.

MAGNEGAS OPENS NEW HEADQUARTERS

MagneGas Corp. officially moved into its new headquarters. The 18,000-sq.-ft. facility is located within an industrial area outside of Tampa, Fla. The building contains more space to demonstrate the company’s technology to potential customers and includes a larger R&D area. The company will bring three gas production units online, doubling current capacity. These units will operate in several shifts, which will allow the company to meet existing demand and expand business.

EDUCATION WORKSHOPS OFFERED

The National Center for Welding Education and Training, Weld-Ed, announced its professional development workshop series, which includes seven training modules for welding educators and industrial trainers. The hands-on, instructional workshops offer welding educators affordable, interactive training conducted throughout the summer of 2016 at teaching facilities located throughout the United States. The seven workshop modules encompass virtually every aspect of the welding profession. Workshop participants earn four continuing education units and 40 professional development hours.

6MAY 2016

http://www.pma.org/news/article.asp?aid=11355http://new.abb.com/service/traininghttp://magnegas.com/https://www.weld-ed.org/

ATTC ANNOUNCES LATIN AMERICA DIRECTOR OF SALES

To further support America Torch Tip’s distribution and supply chain partners, the company named Alex Garcia director of sales for Latin America. Garcia will add all South American countries to his portfolio of regional sales management. He has been managing ATTC’s sales activities in Mexico and Puerto Rico for more than six years and has more than 15 years’ experience working with distributors in a variety of metal fabrication industries.

LEADERSHIP AWARD ANNOUNCED

Duane Miller, manager, engineering services and welding design consultant with The Lincoln Electric Co., received the Robert P. Stupp Award for Leadership Excellence from the American Institute of Steel Construction. The award honors those who, through their leadership, have had an outstanding impact on advancing the use of structural steel in the construction industry, according to the AISC. Miller is a recognized authority on the design and performance of welded connections. In other company news, Lincoln Electric will present a three-day Advanced Aluminum Welding Seminar at its Cleveland headquarters, May 25 to 27. The course is intended for welding engineers, technologists, technicians and shop supervisors and will comprise about 70 percent classroom instruction and 30 percent hands-on welding.

RAISING MANUFACTURING AWARENESS

The Fabricators and Manufacturers Association is partnering with Edge Factor to empower 12 college campuses nationwide with story-driven media and resources. The eduFactor series tells the stories of innovative teams as they work to make their ideas a reality through advanced manufacturing. Based on these stories, Edge Factor creates interactive resources to raise awareness and teach students about the pathways in technical education and advanced manufacturing. For the next 12 months, FMA is providing educators from 12 schools in six states access to eduFactor.

HYPERTHERM MARKS MILESTONE

Hypertherm Inc. marked a major milestone with the production of its 100,000th Powermax45 plasma cutting and gouging system. Introduced in 2008, the Powermax45 grew recognition due to its versatility and design. It is portable and can cut 1/2-in.-thick metal and sever 1-in.-thick metal. In addition, the system is designed for handheld or mechanized cutting and gouging. The 100,000th unit was outfitted with a special commemorative cover and sent to the Gases and Welding Distributors Association Spring Management Conference where it was auctioned off in a silent auction.

NEWS & PEOPLE

7MAY 2016

http://americantorchtip.com/http://www.lincolnelectric.com/en-us/Pages/default.aspx?utm_source=pr_falls&utm_medium=link&utm_campaign=lincoln_electrichttp://fmanet.org/http://edgefactor.com/http://www.hypertherm.com/en-us/

To Submit Press Releases, Send Them to Abbe Miller at amiller@techgenmedia.com

NEWS & PEOPLE

YASKAWA HELPING STEM GROW

Yaskawa Motoman is working with the education community to create workforce models and STEM educational opportunities to support job creation, advance scientific discovery, enhance manufacturing capabilities and drive economic growth. Working to provide organizations with the right products, technology and education to fill the gap between what the industry wants and what educational institutions can provide, Yaskawa is creating innovative products, curricula, training certification and services for the classroom and the industry.

ESAB ANNOUNCES CONTEST WINNERS

Esab Welding & Cutting Products announced the winners of its 2015 “A Cut Above” contest for students in welding and cutting programs at secondary and postsecondary schools. Three individual winners won a cash prize for their essay describing how cutting and welding have influenced their lives. Each member of three winning teams received $500 for their submission of a metal fabrication project that incorporates welding and cutting, including the winners from Denton LaGrone ATC, who constructed eight benches to seat an outdoor class.

8MAY 2016

mailto:amiller%40techgenmedia.com?subject=http://www.motoman.com/http://www.esabna.com/us/en/

Another Exciting Addition to the Techgen Media FamilyThe premier edition of Tube and Pipe Magazine will appear in the October pre-Fabtech show issue of all three magazines in the Techgen family – Welding Productivity, Fab Shop Magazine Direct and Shop Floor Lasers – which will reach an aggregate audience of 280,000 opt-in readers.

Because many of our readers self-selected an interest in tube and pipe fabricating, TPM puts specific editorial emphasis on this key area of metalworking, highlighting critical developments and strategies for those who fabricate tube and pipe products. It supplements our range of manufacturing editorial, enhancing our readership and giving your ad

a better chance of being seen and acted upon.

As is true with all of our magazines, TPM will provide you the chance to embed a video or a direct link to your website in the ad, multiplying your impact.

TPM is your opportunity to reach out and impress prospects in your market. The inaugural issue will close Sept.1. Contact our sales group to reserve your space.

For advertising information, contact:

Alan Berg, Advertising Salesphone: 732.995.6072email: aberg@techgenmedia.com

Neil Kelly, Advertising Salesphone: 610.584.5560 email: nkelly@techgenmedia.com

Announcing Tube and Pipe Magazine

TPMCOMING

IN OCTOBER

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MILLER EXPANDS ARCREACH TECHNOLOGY

Miller Electric Mfg. Co. expanded its ArcReach remote control technology with three machines for portable welding applications in the construction, fabrication and shipbuilding markets. The XMT 350 CC/CV and XMT 450 CC/CV multi-process welding power sources are capable of MIG, stick, TIG and flux-cored welding, along with air carbon arc cutting and gouging. The Dimension 650 power source offers

the same multi-process capabilities with the control needed to weld thin materials and the capacity to handle 3/8-in. carbon arc gouging applications.

PFERD INTRODUCES LATEST GRINDING WHEELS

Pferd Inc.‘s latest depressed-center grinding wheels feature a ceramic oxide grain that provides high stock removal rates and long service life. Suitable for working with steel and stainless steel, the new wheels, designated CO 24 Q SG, have a hardness grade Q and are for a variety of applications, including weld grinding. The wheels are available in sizes ranging from 4 1/2 in. dia. by 1/4 in. thickness and a maximum speed of 13,300 rpm to 9 in. dia. by 1/4 in. thickness and a maximum speed of 6,600 rpm.

ESAB RELEASES NEW NESTING SOFTWARE

Esab Welding & Cutting Products released a new version of its Columbus CAD/CAM nesting software for plasma, oxyfuel, laser and waterjet cutting. This version offers a simplified, customer-influenced user interface. For the parts and plates within a customer’s library that are marked for automatic process, the updated Job Wizard can automatically nest all parts on the correct plates as well as assign the best machine to cut the part based on strategy settings. For job shops, the wizard can perform these functions automatically within minutes after a customer releases the order.

NEW PRODUCTS

FRONIUS’ NEW STICK WELDING MACHINE

Fronius USA LLC’s new energy-efficient TransPocket 150 and 180 single-phase stick welding machines are replacements for the TransPocket 1500. The hand-held welding torches are designed primarily for stick welding and can utilize electrodes with diameters up to 4 mm. These power sources are also suitable for TIG welding up to 220 A, with a new TIG multi-connector and a welding torch with an up/down function at the user’s disposal to adjust the welding current directly on the torch. Two-step and four-step TIG welding is possible with the TransPocket as well as current pulsing.

10MAY 2016

https://www.millerwelds.com/http://www.pferdusa.com/http://www.esabna.com/us/en/http://www.fronius.com/cps/rde/xchg/fronius_usa

CLARCOR RELEASES NEW MIST COLLECTOR

Clarcor Industrial Air’s SHM SmogHog media mist collector uses a three-stage filtration process that progressively reduces the mist concentration resulting in a near 100 percent particle removal efficiency. The primary filter features Peach saturated depth coalescing filter cartridges or optional fiberglass bags, depending on the application. The increased airflow of the filter results in increased capacity and removal efficiency for extended periods of time. The media is incorporated into a filter arrangement that maximizes filter area and allows simple service and maintenance.

NEW PRODUCTS

To Submit Press Releases, Send Them to Abbe Miller at amiller@techgenmedia.com

HOBART ADDS TWO NEW WIRES

Hobart Brothers Co. added two gas-shielded flux-cored wires, FabCO Element 71C and FabCO Element 71M, to its Element family of low-manganese wires. The wires have been formulated to produce manganese emissions below those of other similarly classified filler metals. Both offer enhanced out-of-position capabilities; produce low spatter levels to minimize post-weld cleaning; and have a fast-freezing, easy-to-remove slag to reduce the risk of slag inclusions. They are available in diameters of 0.045 in., 0.052 in. and 1/16 in. on 33-lb. fiber spools.

NEW WELDING APP FROM SANDVIK

Sandvik Materials Technology launched its new welding app for on-the-job functionality to meet welding professionals’ requirements when planning and performing welding projects. It allows users to plan which grades to choose for which jobs, make ferrite calculations, determine the level of heat input for a specific grade and select filler material. Sandvik also launched the Sandvik Welding Handbook, a downloadable and web-generated pdf that contains comprehensive product information and data sheets that feed the welding app.

LINCOLN ELECTRIC’S NEW WELDING SOLUTION

The new Pantheon Mechanized Welding System from The Lincoln Electric Co. offers automated, repetitive welding operations for submerged and open arc processes in the heavy fabrication, shipbuilding, power generation, construction and pressure vessel manufacturing industries. Available in 8-ft.-by-8-ft. and 11-ft.-by-11-ft. sizes, it integrates with other automation systems, including ingoing and outgoing material handling, to enhance workflow. The system comes in a standard configuration that includes Power Wave AC/DC, 1000 SD Welder, MAXsa Controller, and adjusters and slides.

11MAY 2016

http://www.clarcorindustrialair.com/mailto:amiller%40techgenmedia.com?subject=http://www.hobartbrothers.com/http://smt.sandvik.com/en/products/welding-products/welding-handbook/welding-handbook/http://www.lincolnelectric.com/en-us/Pages/default.aspx?locale=1033

Five basic steps to extend the life of heavy equipment through hardfacing

CONSTRUCTIONby Jack Wallin, principle engineer, Stoody, an ESAB brand

The process of hardfacing has evolved from using the oxyacetylene rods invented by the Stoody brothers – Shelley and Winston – back in 1921 to a complex material science that provides application-driven solutions. Hardfacing improves profitability by reducing unplanned downtime and allowing for scheduled maintenance procedures. It does so by using lower cost base metals that are overlaid with a specialized alloy of superior durability to rebuild worn parts rather than replacing them.

With a focus on cost reductions and productivity enhancements, the selection of the correct alloy and proper application is critical. What follows are the five basic steps to maximize hardfacing effectiveness: base metal identification, wear factor identification, alloy selection, weld process selection and bead patterns.

STEP 1. IDENTIFY THE BASE METAL

Base metal type and its carbon and total alloy content are important factors in the hardfacing process.

Some metals tolerate extremes in heat or cold well, while others do not. Common base metals include low, medium and high carbon steels; wear- and abrasion-resistant steels; manganese steel (Mn-steel); stainless steels (300 and 400 series); tool, die and mold steels; and cast irons.

Materials with higher amounts of carbon and alloy content, wear- or abrasion-resistant steels, tool steels, cast irons and 400 series stainless steels may require pre- or post-heat, slow-cool or stress-relief processes to minimize distortion, shrinkage,

cracking and spalling (lifting of the weld deposit) and to reduce thermal shock to the part. Rapid air quenching, the abrupt air cooling from welding temperature, embrittles the part in the heat-affected zone. For higher carbon and alloy steels, preheating greatly reduces this tendency.

The carbon and alloy content of the base metal determines the recommended preheat temperature; the higher the carbon and alloy content of the base metal, the higher the preheat temperatures required.

To determine the best preheat procedure for an application, a trusted hardfacing alloy product representative or distributor can help.

Austenitic Mn-steel requires special provisions to prevent brittleness. Mn-steel is non-magnetic and tough, and it workhardens under high-impact loads. For this reason, Mn-steel parts are often found in machinery that uses high-impact loads to render and crush. Examples include rock crushers, roll and impact crushers, swing hammers and car

Stoody 964 AP-G is an all-position, gas-shielded flux-cored wire that can achieve 64 Rockwell C hardness. It offers improved weldability over chromium carbide and many other tool steel welding wires.

13MAY 2016

For sand or soil containing clay, use a waffle pattern like the one shown here. The overburden packs into the spaces between the weld beads and further protects the base metal.

shredders. Mn-steel parts are often used without hardfacing. Prior to workhardening, Mn-steel has low abrasion resistance. Applying a suitable hardfacing on top of a manganese buildup deposit significantly increases the part life.

The toughness of Mn-steel can be lost if the base metal temperature exceeds 500 F (260 C). Therefore, avoid applying prolonged and concentrated heat to any single area on the part because overheating causes embrittlement. Using higher travel speeds can also help reduce the size of the heat-affected zone.

Weld Mn-steel base metals only with manganese alloy consumables. Avoid using carbon steels as they cause brittle weld deposits that will spall. Stoody Nicromang and Dynamang products in wire or stick electrode forms are commonly applied for buildup and hardfacing in earth moving and crusher applications for impact resistance. Stoody 110 and 2110 can also be used for this as well as for joining Mn-steel to carbon steel.

STEP 2. IDENTIFY THE WEAR FACTOR

Once the base metal has been identified, the next step is to identify the type of wear to

14MAY 2016

which the part is subjected. This is an important factor when determining the best hardfacing alloy to use. There are several wear categories:

• Abrasion-gouging (high impact), accounting for 55 to 60 percent of wear, is caused by high-stress grinding, repeated grinding or crushing against equipment. It can also be caused by low-stress scratching and slow wear from scouring action across equipment.

• Fretting corrosion is encountered when closely fitted metal parts are subjected to vibration loading and stress.

• Corrosion, both galvanic and chemical.

• High-temperature wear results from rapid cooling following high heat.

• High-compression wear results from mechanical stress caused by large compressive loads.

Individually, or in combination, these wear categories determine the best choice of hardfacing alloy to minimize wear and extend part life.

STEP 3. SELECT AN ALLOY

If restoration of a dimension is needed prior to hardfacing, select a buildup material compatible with the base metal and the final overlay. The alloy content of the hardfacing material determines hardness and abrasion resistance. The hardness of the hardfacing bead is not the major factor providing wear resistance; the percentage of carbide and the type of carbide structure in the matrix

Industrial Magnetics, Inc.Call: 888.582.0823 • Surf: www.magnetics.comScan: QR code with your smart device

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Industrial Magnetics, Inc. fabricates innovative and unique magnetic solutions for industrial lifting, holding, fixturing and moving applications as well as wide variety of conveying products for ferrous metal parts, lids, containers and more.

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No Problems!

Stoody 155FC and Stoody 160FC alloys provide weld

deposits comprised of special blends of tungsten

carbides in nickel-silicon-boron matrix systems. They

have been specifically developed for exceptional

weldability and superior abrasion resistance in oil

field applications, such as the stabilizer shown below.

• Adhesive wear (usually metal-to-metal) occurs from scuffing, scoring, galling and seizing (frictional wear).

• Cavitation erosion is metal loss caused by the implosion of vapor cavities at the metal part surface. This occurs in liquid handling systems, pumps, impellers, propellers and hydro-turbine runners.

15MAY 2016

https://www.magnetics.com/default.asp

determine how well a hardfacing overlay will resist wear.

Hardfacing alloys may contain one or more of the following carbide types in the matrix: iron, chromium, molybdenum, tungsten, columbium (niobium), vanadium and titanium. When a hardfacing product forms more than one type of carbide, it is referred to as a “complex carbide.”

if a hardfacing is subjected to a maximum service temperature that exceeds its recommended usage. For applications involving abrasion with high temperature and corrosion, use cobalt- or nickel-based alloys. Tungsten carbide is the best choice to resist metal-to-earth and fine-particle abrasion. Nickel-based tungsten carbide alloys, such as Stoody 160FC or the latest Stoody 160FS, with spherical tungsten carbides, offer superior performance when abrasion resistance in ground engaging applications is warranted. However, it should not be used above 1,000 F (538 C). At higher temperatures, the matrix softens, thus reducing wear resistance.

Deposits with higher alloy contents (and wear resistance) tend to cross check (form hairline cracks across the weld beads). A regular check pattern is beneficial in many applications. It reduces or eliminates distortion. Irregular crack patterns, such as cracks running in the direction of the weld beads, can result in spalling, especially under high impact.

In addition, some hardfacing wires are designed to reduce the amount

of inter-pass cleaning. These alloys produce little or no slag and allow a second pass to be applied without cleaning.

STEP 4. SELECT THE WELD PROCESS

Process selection likely depends on the welding equipment available and operator skill. While hardfacing may be performed using most welding processes, larger scale operations most commonly use the stick, flux-cored, open arc or submerged arc welding process. There are advantages and disadvantages to using each welding process.

Stick welding is the most common process. Hardfacing alloys are easily accessible, can be used for welding on a range of thicknesses and for welding in or out of position. In addition, stick welding equipment is simple and mobile, making it especially suited for field work.

As with stick welding, there are many alloys available for hardsurfacing using the flux-cored or open arc welding process. These wire welding

High-carbon, high-chromium alloys have good abrasion resistance with moderate resistance to impact and corrosion. Where abrasion resistance is the primary performance requirement and deposit cost is a concern, using iron-based, high-carbon and high-chromium hardfacing alloys is a good option. A reduction in deposit hardness and wear resistance may occur

Base metal type and its carbon and total alloy content are important factors in the hardfacing process.

16MAY 2016

processes increase deposition rates and produce welds with good integrity.

While most welding is performed in the flat or horizontal position, wires are available for all-position welding. Stoody’s iron-based non-martensitic all-position wires 964 AP-G, 965 AP-G and buildup AP-G, for instance, can be applied without repositioning of a part, freeing welders to choose whether to apply hardfacing alloys in situ or in a shop environment. Because repositioning is no longer necessary, mobile welding systems can be employed in situ – on location where the part or equipment is in service. This can further reduce costs attributable to longer periods of downtime and resources traditionally expended to disassemble, transport and reassemble heavy equipment requiring maintenance.

Submerged arc welding may make sense when buildup on larger parts is required and they can be welded in the flat position (or, in the case of cylindrical parts, rotated). The process is typically automated. Using the correct flux and wire combination

StoodCor 136 is an open arc wire ideally suited for ID cladding pipe. It provides erosion and

corrosion resistance to meet the needs of tar sands transportation applications.

17MAY 2016

ESAB WELDING & CUTTING PRODUCTS

STOODY

provides the required performance. Using incorrect flux and wire combinations can, however, result in deposit chemistry issues and even part failure.

STEP 5. APPLY BEAD PATTERNS

A cost-saving alternative to hardfacing an entire surface is to apply weld beads spaced from 1/4 in. (6.3 mm) to 5/8 in. (15.9 mm) apart and not in the same direction as the flow of abrasive material across the part. Weld beads applied perpendicular to abrasive flow work particularly well for fine abrasive materials like sand or soils.

For shovel teeth subjected to wear from rock, ore, slag or similar material, apply hardfacing beads parallel to the abrasive material flow. These weld beads will act as directional runners, allowing the abrasive material to ride along the weld beads, protecting the base metal from erosion.

A waffle (crisscross) or herringbone hardfacing bead pattern works well with sand or soil containing clay.

Form the herringbone pattern by laying weld beads at varying angles. The overburden packs into the spaces between the weld beads, affording further base metal surface protection.

Apply a dot pattern to part areas subjected to wear, but not heavy abrasion. Use dot patterns on parts where distortion may be a problem, such as with base metals that are sensitive to overheating. Applications may include Mn-steel or thinner material where embrittlement may occur.

In some applications, hardfacing deposits applied to part surfaces and edges may spall from impact and high-compression side loadings. By applying the hardfacing into grooves cut into the base metal or surrounding impact-resistant weld metals, such as Mn-steel, spalling potential is greatly reduced. This method also extends service life of more brittle hardfacings used under high-impact conditions.

Hardfacing improves profitability by reducing

unplanned downtime and allowing for scheduled

maintenance procedures.18MAY 2016

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MANAGING INFORMATION

by Caleb Krisher, welding information management, Miller Electric Mfg. Co.

Seven questions to ask before purchasing a welding information management solution

Welding information management solutions generate electronic data that can reveal various enhancements, such as a wire or process conversion that could ultimately boost productivity.

As with any technology investment, the decision to purchase a welding information management solution must be made with careful consideration if it is to yield the best results. These systems monitor multiple facets of the welding operation, including arc-on time, deposition rates and general weld parameters. Some systems provide advanced process control to guide weld sequences, duration of the welds and more. The goal is to generate electronic data that can be used to gain insight and drive improvements throughout the operation.

There are several reasons for seeking welding information, including:

• Training less-skilled operators• Increasing productivity, improving

quality and better managing costs• Gaining greater consistency

of welded parts by different operators

• Preventing missed welds• Enforcing proper weld sequence

and required work instructions• Detecting and eliminating weld

defects using high-resolution signature analysis

A welding information management solution can help address these pain points, but several questions should be asked before purchasing one.

• Do you need a welding information management solution that can adapt to multiple brands of welding equipment (mixed fleet), older equipment and new equipment?

Most welding operations have equipment from several different manufacturers. Unfortunately, not all welding information management solutions are compatible with multiple brands. Look for a universal system that works with a variety of brands or consider standardizing your welding equipment so you can purchase a manufacturer-centric solution.

In some cases, it may be enough to select a solution that monitors the productivity and quality of specific welding cells within your fleet to eliminate particular problems, and then, find another way to monitor welding activity on the remaining

20MAY 2016

equipment. However, if all of your new equipment is from the same manufacturer and your old machines are the only outliers, it may be more practical to purchase new power sources to match your dominant brand.

Before making the investment, be sure to ask yourself two important questions. First, “What’s the value if I’m only monitoring part of my fleet versus monitoring the entire shop through a universal system?” Second, “Would it be more cost-effective to find a system that monitors a mixed-brand fleet or to purchase new equipment from one brand in order to standardize the fleet?”

• Do you need a welding information management solution to monitor multiple processes?

Your welding processes, whether you use one or many, affect the type of welding information management solution you are considering. For example, if your shop has sub-arc welding applications and also uses TIG, MIG or flux-cored welding,

determine whether the solution can monitor all of these processes. If so, can it perform in a tailored manner or does it monitor the processes through a one-size-fits-all technology?

Similarly, it is important to consider the market segments and industries you serve – along with any regulatory agencies to which they answer – in order to determine your monitoring needs. Traceability and proof of weld quality is a growing challenge for many companies, especially for tier suppliers and government contracts.

• Is your goal to drive general improvements in productivity and quality, or do you need traceability related to each welded part?

If you need only basic metrics for productivity and quality, it may be more cost-effective to purchase a less sophisticated entry-level welding information management solution that is easy to install, deploy and support. This could include a basic cloud-based system.

A welding information management solution can help train less-skilled operators, gain greater part consistency and prevent missed welds.

21MAY 2016

Conversely, if you need to tie operator productivity to a specific part, calculate cycle times and understand reasons for downtime, consider investing in a more advanced solution. The same is true if there is a lack of consistency on the shop floor, if you need to give operators specific work instructions or if you want a “virtual trainer” to ensure new operators meet production consistency.

An advanced solution can help train new employees quickly and cost-effectively, allowing them to produce parts on par with what veteran operators deliver – without taking valuable time away from those experienced employees to support training.

• Do you need a welding information management system to monitor manual and automated/robotic welding?

Take into account whether you have manual welding, fixed automation or full automation with robotics and programmable logic controllers (PLCs) – where it is necessary for a

welding information management solution to communicate with a robot and a PLC – or an interface with light curtains or fixture clamp verification.

Always make sure you’re shopping for a system that fits with the equipment you have now but can grow with your needs. Invest in a solution that can adapt to your welding operation over the next two to five years and beyond.

• Does your facility have network and internet connectivity at each welding cell and is cloud-based data storage acceptable?

Some welding information management solutions are cloud-based while others are PC-based. It is important to understand your security risks and ensure you have strong networks and firewalls in place or guest networks that can handle the solution you are considering. A well-designed solution will send automatic notifications to managers via email or text message whenever expected weld parameters are not met, enabling the team to take corrective action.

Many entry-level solutions are cloud-based, which may require you to work with your organization to gain security approvals. These solutions provide a turnkey implementation that frees your organization from managing computer servers and database administration. If your company is risk-averse and opposed to using a cloud-based system – or does not want to take the necessary steps to implement the proper networks – consider a product that is PC-based.

It is important to note that a PC-based solution may require the purchase of new computers, monitors and keyboards to place in welding cells. You will need to secure the services of a nearby IT/database administrator who can help with the installation, setup and networking support.

Regardless of whether your solution is cloud- or PC client/server-based, it is also important to have a backup plan in place in the event of a cut

Welding information management solutions provide a turnkey implementation that frees your organization from managing computer servers and database administration.

22MAY 2016

ethernet cable or computer failure. Be sure to have a spare PC available and ready to implement, a good customer service-oriented company you can call to enable another software license on the backup computer and spare ethernet cables on hand.

Welding information management solutions with built-in wi-fi offer another level of simplicity for implementation, in addition to cloud-based storage of your data. In some cases, these solutions offer an extra layer of protection because they provide local data backup on the collection device if wi-fi connectivity to the cloud is lost. Some solutions can only store up to 1,000 welds in memory while others offer up to 30 days of memory, enabling you to get your network back online without loss of welding data.

• Do you need a welding information management system to audit your entire process or quantify the most cost-effective filler metal for your application?

The goal of a welding information management

solution is to generate electronic data that can be used to gain insight

and drive improvements throughout an operation.

Welding information management solutions can help conduct a weld audit of your existing operation by tracking deposition rates and downtime for non-welding activities, such as delays in part delivery or those caused by fit-up challenges prior to welding or grinding spatter in the post-weld stage. By examining these factors, the solutions can also help recognize the most significant bottlenecks in your operation. Additionally, when a solution is in place, it can quickly identify productivity, quality and cost advantages of a filler metal that is more appropriate for your application.

For example, if you are currently using a solid wire that generates spatter during the welding process, it may be beneficial to convert to an alternative product such as metal-cored wire that can provide productivity enhancements, greater deposition rates and potentially less spatter cleanup.

While switching to metal-cored wire may cost more up front per pound of wire, an analysis conducted with your

MILLER ELECTRIC MFG. CO.

welding data may reveal that a wire or process conversion could ultimately save you money by boosting your operation’s productivity.

• Do you have an internal champion with welding application experience and a thorough deployment plan?

To ensure your welding information management solution garners a positive return on investment and helps drive continuous improvement results, you need someone who believes in the solution, who is committed to it and who wants to deliver results – an “internal champion.”

Welding or plant supervisors are strong candidates for the job, but an internal champion could also be a lead welding engineer, a production manager, a production supervisor or even a head maintenance person for welding and fabrication. The most important attribute is strong leadership with the ability to motivate and inspire others. This person should also be organized enough to gather part drawings or photographs of all the welded parts and correctly load them in the system.

Ideally, the internal champion would create a cross-functional team dedicated to assessing the welding data, discussing potential modifications to the welding operation and executing those changes.

A welding information management solution is a big investment but one that can generate significant improvements for companies that choose the right solution for their operation and effectively integrate it. Before making this investment, consider whether your existing

welding equipment is capable of reaching the productivity and quality goals the solution might reveal, and also determine the level of support you need to implement the solution.

Also, be sure to enlist the help of a trusted equipment manufacturer before making a final decision, and decide what return on investment you need to achieve to ultimately consider the investment a success.

24MAY 2016

This person serves as a liaison between top management and operators when installing the system, ensures the right people from the organization are involved in deploying it, and helps identify and address the opportunities it reveals.

Without an internal champion, the likelihood of your solution being successful in the long run is significantly lower. He or she can help generate interest in and acceptance of the new technology on the plant floor by educating operators of its benefits. Because operators play such a vital role in the day-to-day welding process, securing their participation and buy-in is imperative.

https://www.millerwelds.com/http://weldplus.com/

Yaskawa Motoman answers the call for compact workcells for robotic welding

Smallfootprint,

PRODUCTIVITYby Jimmy Myers, senior editor

The American Welding Society last updated a version of its “welding shortage fact sheet” almost a decade ago. So, clearly, the issue regarding the skilled welder shortage is nothing new. But that doesn’t mean that the shortage isn’t being felt today in job shops throughout the country. And while there aren’t as many welders out in the field as there were a decade ago, the demand for high-precision welds still remains.

The welding equipment industry, therefore, is committed to providing solutions to account for the lack of skilled welders. It’s responding with products that fit the needs of today’s job shops and small businesses where welding is a priority. Yaskawa Motoman has built a line of all-in-one robotic welding systems called ArcWorld that include an optional Kinetiq Teaching component, which can significantly reduce the amount of time – and experience – it takes to complete a welding application.

“You and I aren’t going to accept an inferior car,” says Glen Ford, product marketing manager for Yaskawa

Motoman, giving an example of how the skilled welder shortage could affect consumers. “We still want the welds to be good so our car doesn’t fall apart when we’re out on the road. Standards still have to be met. We’re looking at automation and standardization and coming up with new ways to address those needs.”

Yaskawa Motoman’s most recent offering, the ArcWorld C-30, the company’s most compact all-in-one system in the ArcWorld line, tackles a number of customer needs that can be attributed to the shortage of skilled welders and to the desire to make better parts in less time with less cost.

FLEXIBILITY IS KEY

For job shops, flexibility is a major plus. Owners don’t want to turn down orders, which is sometimes the case if the application doesn’t fit their current welding workcell capacity, workforce availability or shop floor layout. They might not have the option, for example, of unbolting safety walls from their floor

and moving them to a more convenient location.

“They still want to produce good quality, replicable pieces,” Ford says. “The ArcWorld C-30 takes components that we already know about: the welding equipment, the shielding, the table, and it puts them into a framework. None of the ArcWorld C-30 components themselves are brand new, it’s just more compact and offers ease of use for the new guy.”

The ArcWorld C-30 isn’t built for a job shop that’s producing the same parts in multiple shifts over an extended period of time. Rather, the system is designed for a job shop with multiple customers having different jobs that require specific applications for limited runs. Therefore, the system can easily be reconfigured for every new application – its welding table is built for customized part fixtures.

“Those job shops,” Ford says of the C-30 users, “don’t know what they’ll be welding two months from now, so they want to be able to reconfigure their workspace.”

The ArcWorld C-30 includes a six-axis arc welding robot, controller with menu-driven arc welding software and pneumatic powered slide-up doors.

The ArcWorld C-30’s safety features include four-sided panels shielding the welding arc coming from the six-axis MA1440 arc welding robot.

26MAY 2016

Ford says they are seeing more interest from job shops already using larger ArcWorld systems that want to use the C-30 positioned near the larger system, feeding it the parts needed for the larger application.

“We’re getting some interest with people saying, ‘hey, this makes sense because I don’t have to bolt everything down,’” Ford explains about the all-in-one component, meaning users don’t have to use safety panels that are often bolted down or heavier equipment that is also bolted down to the floor and basically a permanent fixture on the shop room floor.

In some situations, customers have had difficulty ordering the parts they need for the bigger process, so they bring in the ArcWorld C-30 to make those parts in-house at a fast pace.

BUILD TO THE NEED

Yaskawa Motoman spoke with customers about their needs, which informed their design of the compact ArcWorld C-30 (C stands for compact). Customers want a robotic welding

system that is easy to set up and can be reconfigured to fit their workspace today as well as when those space requirements change in the near to distant future. They want a system where safety is a priority while also allowing them to produce smaller parts more efficiently.

“Those were the driving factors when we started putting it together,” Ford says of the ArcWorld C-30. “That’s why this footprint makes sense. It’s not that we took a larger workcell and said, ‘let’s make this smaller.’ What we did was look at what our customers needed.”

The ArcWorld C-30 includes a six-axis MA1440 arc welding robot, DX200 controller with menu-driven arc welding application software, operator station, integrated welding package and pneumatic powered slide-up doors, which interlock with robotic operations and offer better ergonomics.

There is also safety to consider, and the ArcWorld C-30 complies with U.S. and Canadian safety standards. A barrier guarding has a solid sheet

THE KINETIQ DIFFERENCE

Yaskawa Motoman developed Kinetiq Teaching, a complex engineering solution that makes programming automated welding much easier. It involves manipulating the robot’s movements by hand, bringing the welding tip to the appropriate points and logging those positions into a computer. The once cumbersome task of programming is now as simple as utilizing software and a touch-screen interface.

What once took an experienced robot programmer hours to set up now only takes a bit of “teaching.” Furthermore, automated robotic welding, once an option only for big companies with more flexibility in their budgets and highly trained programmers, is now a possibility for small shops that have Kinetiq Teaching.

With Kinetiq Teaching, the welder doesn’t have to know about algorithms or robotic programming language. They also don’t have to be knowledgeable in the concepts of linear or circular interpolation due to the fact that the software automatically reduces the number of programmed points, offering the most appropriate and efficient trajectory.

The teaching method can save welders between 20 and 50 percent on robotic programming time, which means even shops with low-volume production can see a return on investment after investing in the Kinetiq Teaching option.

27MAY 2016

metal side and back wall. Other safety features include a single point of operator control, enhanced E-stop functionality, integrated speed monitoring, a functional safety unit that monitors the robot and a manual brake release for the robot.

The ArcWorld line includes six other large base series, which come in as many as four different models per series. The V-6000 series, for example, is the largest system, made for high-volume work and can be equipped with multiple welding robots for high-performance welding applications. While it’s the largest workcell in the ArcWorld series, it takes up 44 percent less workspace than workstations where the robots are mounted in an overhead configuration.

FINDING THE ROI

While the customer is always focused on cost, Ford says the return on investment is equally important. For instance, the ArcWorld C-30 – as well as the other models in the ArcWorld series – has the optional Kinetiq Teaching component (see sidebar),

which adds to the cost of the unit. However, if it’s going to save the customer money in 12 months, from a business perspective, Ford says it makes sense to invest in the add-on.

“Our approach is to find out if it makes sense for you,” he says, adding that if a customer wants to teach the robot 100 different weld points, they might be better off rethinking their process. However, for the right applications, Yaskawa Motoman has found the Kinetiq method to be 30 percent faster than the independent method.

Ford says that with the Kinetiq Teaching component, a job shop’s master welder can set up the process and someone less skilled can come in and feed the materials and run the parts.

“Technology is great,” Ford says, “but if it doesn’t help you do something better or faster, or save you money, then it’s just technology.”

YASKAWA MOTOMAN

The ArcWorld series maintains a small footprint, but can be expanded to higher-production jobs that require additional robotic welders.

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by Kirk B. Beaster, market manager, surface treatment, Chemetall U.S. Inc. 

To produce high-quality products with long life, removing weld scale prior to coating is a must

TIPPING THE S C A L E

Figure 1. Areas of the heat-affected zone.

Figure 2. Examples of weld scale adjacent to a weld.

From buses to bicycles, vehicles have to battle the elements. And the same goes for steel railings and any other metal-made product that spends its lifespan outdoors. To keep rust at bay, fabricators finish their metal products with a variety of corrosion-resistant coatings and paints. Whether that coating can properly form and stick inevitably makes or breaks a product in the face of harsh weather conditions.

In addition to their corrosion-resistant finishes, bikes, buses and balconies have another common bond: welded assemblies. When products require welds as well as coatings, fabricators are faced with the possibility of weld scale forming, which hinders a coating’s ability to adhere to a welded

surface. And this isn’t exclusive to products that are made for the outdoors. Any metal product that requires a coating or paint can be compromised if weld scale is present.

Weld scale is a type of weld soil that stains or discolors the welded metal and the area around it. The degree of the weld scale depends on the type of welding method being utilized. To ensure the success of the subsequent pretreatment and coating operations, weld scale must be removed.

To properly manage weld scale, fabricators must first understand how it is created. From there, they must choose the best way to remedy it, to keep their products’ coatings in tact – even through the deep of winter.

IDENTIFYING WELDING SOILS

The inorganic soils created during the welding process are localized in the area adjacent to the weld. These soils include weld spatter, weld slag, weld scale and various elements that can be found in the weld filler metal.

The area that displays the effects of the welding process is referred to as the heat-affected zone (HAZ). The HAZ is the area of base material that is not melted but has had its microstructure and mechanical properties altered by welding.

The heat from the welding process and subsequent recooling causes the changes in the HAZ. The extent of the property changes depends primarily on the base material, the weld filler metal, and the amount and concentration of heat input by the welding process.

For example, TIG welding creates a high-temperature electric arc that is focused on a small area. The intense heat coupled with the slower weld speed typically used for TIG may result in a wider HAZ. The arc in MIG welding may produce temperatures similar to TIG welding, but the weld

30MAY 2016

speed is faster with MIG. When comparing the two welding methods on the same base material, MIG welding typically results in a smaller HAZ than TIG. The areas of the HAZ are shown in Figure 1.

WELD SCALE

Weld scale is an oxide layer created from the exposure of the heated base material to the surrounding oxygen-containing environment. The extent of the weld scale is dependent on the amount of heat generated during the welding process and is a visual indication of the extent of the HAZ.

The presence of weld scale inhibits the ability for a conversion coating to form and does not provide a receptive surface for the adherence of the coating. Even if initial adhesion of the coating is observed, the scaled areas have inferior corrosion resistance and must be removed to ensure the long-term performance of the coating. Examples of weld scale are shown in Figure 2.

If coating-adhesion failures on improperly prepared welds

occur before the products ship to a customer, they are typically reworked. Reworking the part may include sanding and repainting the affected area ,or it may include stripping or blasting the coating or paint from the entire part and reprocessing it through the surface treatment and paint operations. This results in increased process delays due to loss of production, increased labor costs and added material costs.

If the coating-adhesion failures occur at the customer site (field failure), the results can be damaging to a company’s reputation. Besides customer dissatisfaction, there may also be monetary penalties. A minimal amount of field failures typically results in warranty claims. Numerous failures may lead to large-scale returns of product with refunds expected or, ultimately, the loss of contracts.

REMOVAL OF WELD SCALE

The formation of the proper pretreatment conversion coating and adhesion of subsequent coatings to welds is influenced by the cleanliness of the weld area. Therefore, weld

It’s imperative for fabricators to manage weld scale to properly coat their

products to give them strength and longevity.

31MAY 2016

http://vibroindustries.com/

CHEMETALL U.S. INC.

soils – whether it’s weld scale, slag or spatter – must be removed to provide a receptive surface for subsequent conversion coating and coating applications.

There are two methods of removal: mechanical and chemical. Mechanical methods consist of manual or automatic abrasion. The typical mechanical methods used are grinding, sanding or blasting. Grinding and sanding can be done using abrasive wheels or belts as well as power abrasive brushes (wire brushes). Blasting is typically done using abrasive blast cleaning or abrasive media blasting.

The chemical method typically utilizes an acidic pickle solution, which is recommended, although neutral organic compounds have been used in specialized circumstances.

The acid pickle solution can be applied via spray or immersion and is typically integrated into the surface treatment operation. Thixotropic or gel products also are available that can be applied by non-atomizing,

low-pressure spray or by brush in manual operations.

The types of acid pickle products commonly used for ferrous base materials contain primarily phosphoric acid or sulfuric acid with additional organic acids and additives. It is also common to see mixed acid products such as phosphoric/sulfuric acid or citric/sulfuric acid.

Whatever the method, it’s imperative for fabricators and manufacturers to manage weld scale in order to properly coat their products to give them the strength and longevity that customers expect.

32MAY 2016

The presence of weld scale inhibits the ability for a conversion coating to form and does not provide a receptive surface for the adherence of the coating.

http://www.chemetall.com/

by Stuart D. Bagley, IAQ-EMF Consulting Inc.

How arc welders and the electromagnetic fields they produce

affect employees with pacemakers and ICDs

HEALTHY

In the last decade, there has been increased public concern about exposure to low-frequency electromagnetic fields (EMFs) and radiofrequency fields (RFs). And in some instances, these fears are not unfounded. For people with cardiac-assisting devices, such as an implantable cardioverter defibrillator (ICD) or pacemaker, these devices may be temporarily inactivated or made to operate improperly upon exposure to strong EMFs and RFs.

Those concerns carry over for employers who have welding operations in their facilities – specifically, employers with MIG, TIG or other arc welding equipment as it has the potential for causing harmful interference with employees who rely on an ICD or pacemaker. For these employers, it’s advised to evaluate the EMFs and RFs in the workplace to protect the organization’s most valuable assets: its employees.

LIFESAVING DEVICES

An ICD is a device that is implanted under the skin of patients that are at risk of sudden death due to ventricular fibrillation. The purpose of this device

A welder who has an ICD or pacemaker

should consult with their doctor before

taking on a job that involves

exposure to arc welding operations.

Employers with MIG, TIG or other arc welding equipment should be aware of employees with cardiac devices because the equipment has the potential for causing harmful interference with ICDs and pacemakers.

enough or if there are blocks in the heart’s electrical conduction system preventing the propagation of electrical impulses from the native pacemaker to the lower chambers of the heart.

According to the American Heart Association, each month, 10,000

is to provide defibrillation if the heart enters a potentially lethal rhythm. A pacemaker is a device designed to regulate the beating of the heart. The purpose of an artificial pacemaker is to stimulate the heart when the heart’s native pacemaker is not fast

people are implanted with an ICD. Each year, nearly 600,000 people receive an implantable pacemaker or defibrillator. Taking those numbers into consideration, it’s highly likely that someone with an ICD or pacemaker may be working in the vicinity of arc welding operations.

HAZARDOUS FIELDS

EMFs are generated when an electrical current passes through a wire or electrically operated device, which can interfere with an ICD or pacemaker. With welding, when the welding current flows through an arc welder and its cables, an EMF may be created near the welder’s chest area, where the implanted cardiac device is located.

In addition to arc welding equipment, other equipment that can be found in industrial environments that may interfere with ICDs and pacemakers includes drive motors, especially DC driven, as well as battery-powered, cordless power tools, drills and electric screwdrivers.

RFs are generated by devices such as cellular phones, two-way

34MAY 2016

radios, CB radios and broadcast towers. Occasionally when the source of RF radiation is close to the implanted cardiac device, it may interfere with the proper functioning of a pacemaker or ICD. The result, such as asynchronous (irregular) pacing of the heart by the device among other known effects, is potentially life threatening. Typically, the device reverts to its intended operating state when moved further away from the offending source.

In the case of arc welders, it is recommended to maintain at least a 24-in. separation between the arc welding equipment’s cables, arc, transformer and an implanted cardiac device. Often times, this is not a difficult task, considering employees with an ICD or pacemaker should not be welding in a facility, but instead performing other job functions.

A welder who has an ICD or pacemaker should first consult with their doctor before taking on a job that involves exposure to arc welding operations. Some doctors may suggest against a line of work that involves heavy arc welding.

TESTING THE WORKPLACE

One way of assuring employee safety for those with implanted cardiac devices is to test the workplace for EMF and RF strength. This is done by surveying the facility with specialized meters that detect the location and strength of those fields. 

Specialized meters are available from a variety of manufacturers, such as Extech Industries. These types of meters are typically easy to use to determine EMF levels in the employee’s work area when a survey is undertaken. Importantly, measurement is equipment-specific, not area-wide. EMFs tend to be significant within a few feet from the source. The exception is overhead high-voltage power lines. They can sometimes produce an EMF measured in “volts per meter” over a wide area, depending on the voltage and location of the power lines.

The ensuing results can serve as a roadmap to ensure the safety of the employee. Those areas determined to be problematic can be dealt with by shielding of the source(s) or avoidance of those areas known to exceed safe guidelines.

Specialized meters are typically easy to use to

determine EMF levels in the employee’s

work area.

MINIMIZING EXPOSURE

Pacemaker and ICD manufacturers and several non-governmental bodies have created voluntary standards for exposure to EMF and RF radiation sources for those with and without cardiac implants. Those standards include those of cardiac device manufacturers, such as Boston Scientific CRM, Medtronic CRDM and St. Jude Medical; the American Conference of Governmental Industrial Hygienists; and the Federal

35MAY 2016

Communications Commission in the case of radiofrequency broadcasts.

It may be desirable to hire an independent EMF consultant when surveying large areas or when exact measurements are critical. An individual’s physician, however, should always be the first point of contact when concerns of EMF exposure arise.

All welders – even those without implanted cardiac devices – should understand the proper methods to minimize exposure to EMFs while welding. The Lincoln Electric Co. recommends that welders route their electrode and work cables together, securing them with tape or tie wraps when possible. It’s explained

that “if the cables are routed together, the EMF at that point is reduced. Some cables even include electrode and work conductors inside one cable which may be a convenient way to reduce EMF exposure.”

Proper welding techniques, according to Lincoln Electric, also include connecting the work cable to the workpiece as close as possible to the area being welded. Furthermore, the company says a person should never coil the electrode or work cables around their body and never place their body between the electrode and work cables.

As mentioned, keeping a safe distance from the welding power source reduces the potential for EMF exposure. To further reduce the possibility of exposure, welders can – when possible – weld at the lowest DC output settings acceptable for the welding application.

According to the American Heart Association, each month, 10,000 people are implanted with an ICD. Each year, nearly 600,000 people receive an implantable pacemaker or defibrillator.

EXTECH INDUSTRIES

IAQ-EMF CONSULTING INC.

THE LINCOLN ELECTRIC CO.

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http://www.extech.com/http://www.emftesting.net/http://www.lincolnelectric.com/en-us/Pages/default.aspxmailto:aberg%40techgenmedia.com?subject=

MORE INFORMATION IS JUST A CLICK AWAY!

Fabricators have a triple-barreled resource they can reach through Welding Productivity, or through our sister publications, Shop Floor Lasers and FAB Shop Magazine Direct. Together, we cover fabricating topics from different angles, each with a different focus, linked to give you more depth or a different take on the topics you see in one of the three.

Follow the links to see the latest coverage from our magazine group. More information is just a click away, no matter where you start:

TECHGEN MEDIA’SINFORMATION FOR FABRICATORS IS BIGGER THAN WELDING PRODUCTIVITY

TRAINING WELDERS:Practice makes perfect

FINGER ON THE PULSE:Tracking data in real time

THE INFORMATION CONDUIT FOR FABRICATING AND STAMPING PROFESIONALS

PATH ACT:Understanding investment benefits

SMOKE COLLECTOR: Considerations for dust and fume collection

http://www.fsmdirect.com/http://www.shopfloorlasers.com/http://magazine.fsmdirect.com/2016/apr/d/#page7http://magazine.fsmdirect.com/2016/apr/d/#page19http://magazine.shopfloorlasers.com/2016/mar/d/#page40http://magazine.shopfloorlasers.com/2016/mar/d/#page24