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Ultrasonic Welding

Ultrasonic Welding is mainly used to join and assemble plastic parts and non-ferrous metals.

How does it work?

Ultrasonic welding uses an acoustic tool called an ultrasonic horn. The plastic or metal is melted by conversion of heat through friction. The main components of an ultrasonic welding system are the actuator and power supply, along with the stack.

What are the benefits?

• Speed and ease of welding
• Practical real time quality control
• High quality of welds
• Lower energy consumption than comparable methods
• No need to cool by water
• No need for filler metal
• Efficient weld of copper to aluminum
• Suitable to automation
• Environmentally friendly

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How to Prevent Flash Burns

Let's face it...welding can be dangerous. And accidents happen. Flying sparks and excessive heat certainly lend themselves to the idea of getting hurt. But it doesn't have to happen. That's why it's so important to always keep safety in mind when welding and learn to weld properly.

But, like we said, accidents happen. Flash burns, or welder's flash, is one of the most common welding injuries. It's often described as a feeling of sand in the eyes or basically a sun burn on your eyes.

How Do You Avoid It?

By always wearing proper eye protection when welding. The farther away you are from the arc, the less likely you are to injure your eyes.

What If It Happens to You?

Get to the doctor as quick as possible.

Metro Welding Supply has what you need!

Of course you can easily get all of your welding supplies and welding equipment from Metro Welding Supply. To learn more about our many services or products, please contact us today.

Electroslag Welding Basics

Electroslag welding (ESW) is a highly productive, single pass welding process for thick materials in a vertical or close to vertical position. It is similar to electrogas welding, except the arc starts in a different location. An electric arc is initially struck by wire that is fed into the desired weld location and then flux is added. Additional flux is added until the molten slag, reaching the tip of the electrode, extinguishes the arc. The wire is then continually fed through a consumable guide tube into the surfaces of the metal workpieces and the filler metal are then melted using the electrical resistance of the molten slag to cause coalescence. The wire and tube then move up along the workpiece while a copper retaining shoe is used to keep the weld between the plates that are being welded.

ESW Common Uses

Electroslag welding is used mainly to join low carbon steel plates and/or sections that are very thick. It can also be used on structural steel if certain precautions are observed.

Advantages of ESW

• Joint preparation is much simpler than other welding processes.
• Thicker steels can be welded more economically.
• ESW gives extremely high deposition rates.
• Residual stresses and distortion produced are low.
• Flux consumption is very low.
• No spattering or intense arc flashing occurs.

If you would like any additional information on Metro Welding Supply’s services or products, please contact us today.

The Lay Wire Technique

Metro Welding Supply is happy to share our techniques and knowledge with you in order to help you learn more about the world of welding. We hope that our blog articles help you to achieve a better understanding of welding basics and general knowledge.

A common technique for tig welding is called the "lay wire" technique. Essentially during this process the tig welding filler wire is held in the weld puddle the entire time instead of being dipped in and out as with traditional tig welding techniques used for sheet metal.

Metro Welding Supply has the welding products you need no matter what process or technique you might be using.

And don't forget that you can find us on Facebook and Twitter where you share your welding experiences.

Spot Welding Basics

Spot welding is a resistance welding method used to join up to four overlapping metal sheets typically up to 3 mm thick each. In the process of spot welding, or RSW, work-pieces are held together under pressure exerted by two electrodes. The copper alloy electrodes concentrate welding current into a small "spot" while simultaneously clamping the sheets together. A large current is forced through the spot melting the metal and forming the weld.

Spot Welding Advantages

• Efficient energy use
• Limited workpiece deformation
• High production rates
• Easy automation
• No required filler materials

One of the drawbacks of spot welding is the potential for expulsion. This is the result of excessive heat application and causes the material to thin. The common method of checking a weld is a peel test, although the best way to test is the tensile test, which is much more difficult to perform, and requires calibrated equipment.

Spot welding is used extensively in the automotive industry— cars can have several thousand spot welds.

Now that you've learned a bit about spot welding, how about some help finding the proper welding products and welding accessories for your welding needs?

Stud Welding Basics

The process of arc stud welding (SW) involves joining a metal fastener (weld stud) to a workpiece. The metal fastener is joined under pressure once sufficiently heated with an electric arc. The fastener or weld stud is positioned for welding through the use of a stud gun. When the operator activates the stud gun trigger, the fastener (electrode) is welded to the workpiece without the use of filler metal. One of the big advantages of this type of welding is that the welding duration is typically one second or less.

Stud Welding Uses

Stud welding has a great number of practical applications in carious industries such as automotive, ship building, aero-dynamics, boilers, light and heavy construction, pre-assembled fabrication designs and fit-up parts design. The process can can also be utilized on a range of material thickness.

Advantages

• Major design specifications may be readily adapted to the process, such as material types, metallurgical aspects, special thread designs, fit-up tolerances, etc.
• Produces a minimum of base metal distortion or surface disruption.
• Easily used in locations which do not permit use of other fastening methods.
• Welds are less costly per unit than other methods.
• Requires much less time for training.
• Inspection time is cut down drastically.

Equipment

Some of the equipment that is needed for stud welding:

• Constant Current (CC) Power Source
• Stud Welding Gun
• Weld Cable With Stud Gun Control Card
• Work/Ground Cable With “C” Clamp Type Connector

Should you need help in finding the proper welding products for your Stud Welding needs, please contact us.

What Is Brazing?

As you are learning to weld, it's important to learn the different processes to become a more well-rounded welder. One of these important process is called Brazing.

So what is Brazing?

Brazing is similar to soldering. It joins two pieces of base metal when a melted metallic filler flows across the joint and cools to form a solid bond. Brazing creates an extremely strong joint, without melting or deforming the components. Two different metals, or base metals such as silver and bronze, are perfect for brazing. Brazing can be used to make a bond that is invisible while being resilient to various temperatures. Brazing joints are also know to withstand jolting and twisting motions.

What can Brazing be used for?

Pipes, rods, flat metals, or any other shape can be used in brazing as long as the pieces fit neatly against each other without large gaps.

As with other commonly known types of welding, you must clean the entire area to be joined. Otherwise, you will have an inconsistent joint.

Braze comes in a stick, disc, or wire, depending on your preference or the shape of the joint. If the brazing has been performed correctly, the bond will be nearly unbreakable.

Brazing Advantages

Brazed joints are smooth and complete. Only brazing can join dissimilar metals, such as wrought iron, bronze, aluminum, steel, and copper, with different melting points.

Metro Welding Supply has what you need!

Of course you can easily get all of your brazing supplies and welding equipment from Metro Welding Supply. To learn more about our many services or products, please contact us today.

Metro Welding Is Here For You

Not sure exactly what you need? We know that sometimes it can be a little confusing trying to figure out exactly what welding accessories and products you need, but fear not, Metro Welding Supply can help you determine precisely what products will work best for you and see that you receive your items as quick as possible.

We have the knowledge, experience, and programs to troubleshoot and problem-solve your gas related problems.

Rentals

Metro Welding Supply also offers equipment rental as well as equipment repair.

Contact Us

We are always here for all of your welding accessories and supplies. Don’t hesitate to contact us, should you have any questions.

Total Gas Management

Among all of the great services Metro Welding Supply offers, our best has to be the Total Gas Management Program.

Reduced Costs

One of Metro Welding Supplies’ competitive advantages has been to provide the highest possible level of service our customers could find. With our Total Gas Management Program, we are accountable to all phases of your gas operations---design, supply and performance. This results in significant reduction in gas usage, lower maintenance cost, higher standards of safety, improved employee morale and efficient company operations. Here is a comprehensive look at the highlights of this successful program:

• Ordering
• Equipment Selection
• New Equipment Installation/Start-Up
• Cylinder Transport and Hookup
• Gas Piping Systems
• Dewar Filling
• Safety Evaluation and Training
• Monthly Performance Reports
• Cylinder Tracking
• Vendor Managed Inventory
• Supplier Management
• Incoming Cylinder Inspections
• Annual System Wide Inspections
• Counter-Terrorism Initiative
• Code Compliance Review

Metro Welding on Facebook & Twitter

Stay up to date with what's new at Metro Welding Supply.

We are pleased to announce that you can now find us on Facebook and Twitter.

Please check us out on those great social networking sites. We will be posting new information to keep you informed.

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Tracking Cylinder Capability

Say goodbye to lost/stolen cylinders. Metro Welding Supply has the capability of tracking cylinders. Our barcode system, will track the location of your cylinders, when they leave our dock and when they are returned to us. Stolen cylinders that are returned by another party will not receive credit. Our bar coding system tells us who originally rented the cylinder and who should receive the credit for returning the cylinder. For more information about this system, contact sales@metrowelding.com.

We track our cylinders in a "closed loop" system. This means that we can scan them internally and externally when we move or fill them. This results in accurate cylinder balances that you can trust. We will stop other parties from getting credit for returning your cylinders. If you have multiple jobsites and locations, we'll keep these balances straight.

You can learn more about our other services here or contact us for more information.

Becoming A Professional Welder

Becoming a professional welder is definitely not something for everyone. But for those that aspire to become such, understanding just what it takes can help find the path to becoming a professional in this field. A true professional welder is someone who has been trained and holds certification(s) in welding. Insurance coverage is also of vital necessity. A professional has the ability to work for any person or business who requires their services.

A must have for a professional welder is a proper welding set up, either a small industrial unit or a welding truck. Any pro needs to have every piece of welding equipment needed and may have multiple welders such as MIG, TIG and stick welders for different job types.

If you're looking to become a professional in the fine art of welding, then one of the first major steps would be to seek professional accredidation in welding. Then you will be able to start supplying your welding expertise to those in need of your services.

And of course you get all of your welding supplies and equipment from Metro Welding Supply. services or products, please contact us today.

FCAW: Flux-Cored Arc Welding

FCAW or Flux-Cored Arc Welding A similar type of wire-feed welding is FCAW. It is slightly different from MIG welding in that it does not require a shielding gas. This gas-free welding uses flux-cored welding wire to shield the arc. Along with being the simplest type of welding, it is also very efficient and extremely effective, especially when welding outdoors in windy conditions.

First developed in the early 1950s, FCAW was meant to be an alternative to shielded metal arc welding (SMAW). The advantage is that the use of stick electrodes in SMAW is unnecessary. This has helped FCAW to overcome many of the restrictions associated with SMAW.

Like MIG Welding, FCAW is easy to learn and can create clean welds on steel, aluminum and stainless.

Interested in learning more about other types of welding? Check out our other articles. For questions about our welding products, please contact us.

Forehand vs. Backhand Welding

Forehand welding is often called Puddle or Ripple Welding. In this method, the rod is kept ahead of the flame in the direction the weld is being made. Point the flame in the direction of travel and hold the tip at an angle of about 45 degrees to the working surfaces. This flame position preheats the edges you are welding just ahead of the molten puddle. Move the rod in the same direction as the tip, and by moving the torch tip and the welding rod back and forth in opposite, semicircular paths, you can distribute the heat evenly. As the flame passes the welding rod, it melts a short length of the rod and adds it to the puddle. The motion of the torch distributes the molten metal evenly to both edges of the joint and to the molten puddle.

This method is ideal because it permits better control of a small puddle and results in a smoother weld.

In backhand welding, the torch tip precedes the rod in the direction of welding and the flame points back at the molten puddle and completed weld. The welding tip should make an angle of about 60 degrees with the plates or joint being welded. The end of the welding rod is placed between the torch tip and the molten puddle.

Less motion is used in the backhand method. If you use a straight welding rod, you should rotate it so the end rolls from side to side and melts off evenly. You might have to bend the rod when working in confined spaces. If you do, it becomes difficult to roll a bent rod, and to compensate, you have to move the rod and torch back and forth at a rather rapid rate. When making a large weld, you should move the rod so it makes complete circles in the molten puddle. The torch is moved back and forth across the weld while it is advanced slowly and uniformly in the direction of the welding.

The backhand method is best for welding material more than 1/8 of an inch thick. The backhand method requires less welding rod or puddling as the forehand method.

By using the backhand technique on heavier material, you can increase your welding speed, better control the larger puddle, and have more complete fusion at the weld root.

Be sure to keep your eye out for more upcoming welding articles. Should you have any questions or concerns, please feel free to Contact Us.

What is Tack Welding?

Tack welding is used mig, tig, and arc welding. Basically, it is a small weld that is placed in critical positions of a project or work piece to hold it in place and keep it square as well as to prevent warping.

Tack welding is an essential element during the initial fit up and measuring of welding processes.

The great advantage of tack welds lay in the fact that they are so small that if you make a mistake, all you need to do is simply grind it away; whereas with a large full weld it can be much more complicated to fix bad weld.

Don’t forget to read our articles about MIG and TIG Welding as well. And we are always here for all of your welding accessories and supplies. Don’t hesitate to contact us, should you have any questions.

A Brief History of Welding

The history of joining metals together can be traced back several millennia, with some of the earliest examples stemming from the Bronze and Iron Ages. During the Middle Ages, blacksmiths pounded heated metal repeatedly until bonding occurred.

Thanks to advances in arc welding, and the development of oxyfuel welding led to more technological and scientific advances which have helped make welding much more prevalent in industry. During World War I, arc welding was used for airplanes. With the utilization of hydrogen, argon and helium for welding practices, arc welding became much more common throughout World War II and the 1930s.

In the latter half of the 20th Century, breakthroughs came by way of electron beam welding, laser beam welding, and ultimately robot welding.

Contact us for information or to help you find the right welding supplies for you.

Need A Power Supply

In order to supply the electrical energy necessary for arc welding processes, a number of different power supplies can be used. The most common welding power supplies are constant current power supplies and constant voltage power supplies. In arc welding, the length of the arc is directly related to the voltage, and the amount of heat input is related to the current. Constant current power supplies are most often used for manual welding processes such as gas tungsten arc welding and shielded metal arc welding, because they maintain a relatively constant current even as the voltage varies. This is important because in manual welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc length and thus voltage tend to fluctuate. Constant voltage power supplies hold the voltage constant and vary the current, and as a result, are most often used for automated welding processes such as gas metal arc welding, flux cored arc welding, and submerged arc welding. In these processes, arc length is kept constant, since any fluctuation in the distance between the wire and the base material is quickly rectified by a large change in current.

Have questions? Contact us for more information or to help you find the right Power Supply for you.

Stick Welding Basics

Stick welding (SMAW), the most basic of welding processes, has been the most popular method for most home-shop welding for a long time. Stick welding uses an electric current flowing directly between a gap between the metal and the “stick” or arc-welding electrode. The current causes part of the electrode to melt, allowing it to mix with the metal of the work piece and form the weld. The electrode has a flux coating that burns to form a protective shield around the arc. Stick welding is the most effective method for welding many different alloys or joints. Stick welding can be used outdoors or indoors or in drafty areas, is the most economical method and will weld on rusty or dirty metals.

Benefits of stick welding include:

• Equipment is simple, inexpensive, and portable.
• Electrode provides and regulates its own flux.
• Lower sensitivity to wind and drafts than gas shielded welding processes.
• All position capability.

Stick welding does have some disadvantages though. For instance, it is limited to metals no thinner than 18 gauge, requires frequent rod changing, has lots of spatter and the welds must be cleaned up after they are finished. Stick welding is also more difficult to learn and use, particularly in striking and holding the arc.

If you would like any additional information on Metro Welding Supply’s services or products, please contact us today.

Learning to Weld: Lighting Your Torch

Lighting a torch can be very easy or quite difficult. It depends on your procedure and the type of torch. First of all, be sure to use a spark lighter, not a butane lighter! A butane lighter in proximity to a torch is an accident waiting to happen. That small container of butane packs enough explosive power to maim or kill if a spark should melt through it.

Turn on the fuel just a little and hold the lighter so that fuel is trapped in the spark cup, this is especially important with a propane torch, which can be hard to light if it is cold. Operate the spark lighter and with even a small amount of luck you should have a flame.

Once you have your torch lit, open the fuel and oxygen valves a little at a time alternately until you get the size flame you need. If you have too much fuel, then the flame will burn with a yellowish color due to oxygen starvation. Too much oxygen is harder to see, but should be avoided if possible. Start with too much fuel, a yellowish flame then open the oxygen slowly. You will see a bluish cone start to form in the center of the flame. As you open the oxygen valve the cone will become smaller and more distinct. Just as it's boundary becomes solidly defined, stop adjusting. This is the hottest flame and does not waste either gas or oxygen. Too much gas or oxygen cools the flame and wastes gas. Too much oxygen can also oxidize your workpiece.

The handling of a torch can only be learned by experience. If you move the torch too slowly, you risk melting holes in your workpiece. Too fast, and your workpiece may never get hot enough. The object is to apply just enough heat to do the job. If you are unsure, it may be best to practice on a piece of scrap material first.

Be sure to keep any eye out for the next article in our Learning to Weld series.

More information about out welding equipment and supplies can be found here. Should you have any questions, please contact us for more information.

Precautions for Underwater Welding

Technology for underwater welding has increased greatly, but it is very important to follow all safety precautions when performing this risky venture.

For the person doing the welding, there are a number of risks to be aware of. Obviously there is the potential risk of electric shock. Therefore, it is extremely important for adequate electrical insulation of the welding equipment, along with shutting off the electricity supply immediately after the arc is extinguished, and limiting the open-circuit voltage of welding sets.

There is also the risk of pocket build-ups of gas which are potentially explosive. Yet another harmful risk is the possibility of nitrogen introduced into the bloodstream during exposure to air at increased pressure. Necessary precautions should include the provision of an emergency air or gas supply, stand-by divers, and decompression chambers to avoid decompression sickness following saturation diving or too rapid return to the surface from a deep dive.

More information about out welding equipment and supplies can be found here. Should you have any questions, please contact us for more information.

Welding Titanium

When it comes right down to the actual process of "running the bead," as welders say, welding titanium actually only differs slightly from any other ferrous metal such as steel or stainless steel. As long as some key elements are controlled, welding titanium can be done by almost any experienced welder.

Some of the most important steps take place before and after the actual welding occurs. Eliminating the impurities on the material is first and foremost. Clean material is absolutely crucial to the overall integrity of the titanium weld. This can be achieved through chemical cleaning. Even microscopic bits left behind from a grinding disk, or the oxidized surface itself must be removed. The natural oils on the skin can even contaminate the filler rod. All of these surfaces must be as clean as possible.

Once all of the surface impurities are eliminated, the next factor to consider is the atmosphere, since the actual air around the titanium weld can cause problems. There are several ways to overcome this dilemma. Specialized equipment is available for welding titanium, depending on the available budget. Trailing cups can work for short jobs; however, for production, a small investment of a vacuum-controlled chamber might be in order.

A camber is as expensive as it sounds, but is a worthwhile consideration because heat naturally spreads into the surrounding material. This is known as the heat affected zone or HAZ. Oxygen can and will react to titanium at temperatures just below its melting point, and therefore cannot come into contact with the HAZ while it is still above a certain temperature. The entire area of the HAZ must be constantly purged with pure argon until the surface temperature no longer reacts to the oxygen in the atmosphere.

By controlling these key variables, your chances of successfully welding titanium will greatly improve. However, tt is important to note that welding titanium is considered a very expensive process; and is not recommended for anyone who may still be learning the art of welding.

Should you have any questions about special equipment for titanium welding, please contact us to see how we can help.

Welding Thin to Thick Sections

When welding you may encounter a situation where you will need to weld a thin section to a thick one. Although this may seem an impossible task, there is a solution.

Part of the problem lies in the difference of heat quantity between the two. The thick element absorbs a large quantity of heat before reaching melting temperature whereas the thin tube melts almost immediately. So, in order to weld properly, you need to change the configuration of the joint so that the difference in thickness is kept to a minimum.

The bar or plate has to be machined so that at the joint location the thickness be comparable to that of the tube, or an intermediate transition element of proper shape and size must be welded between the two elements. Alternatively, if the joint shape permits it, you should consider brazing or friction welding.

Need welding equipment? Metro Welding is here for all of your welding supplies, welding equipment, welding tools, and welding accessories. Check out our products or contact us to see how we can help.

How Should Preheat Be Measured?

Steel Welding Code states that preheat and all subsequent minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the thickness of the thickest welded part, but not less than 3 in. [75mm] in all directions from the point of welding.

When preheat is specified, the entire part should be thoroughly heated so the minimum temperature found anywhere on that part will meet or exceed the specified preheat temperature.

Be sure to keep your eye out for more upcoming welding articles. Should you have any questions or concerns, please feel free to Contact Us.

What is the Interpass Temperature?

Interpass temperature refers to the temperature of the steel just prior to the depositing of an additional weld pass. It is identical to preheat, except that preheating is performed prior to any welding.

When a minimum interpass temperature is specified, welding should not be performed when the base plate is below this temperature. The steel must be heated back up before welding continues.

A maximum interpass temperature may be specified to prevent deterioration of the weld metal and heat affected zone properties. In this case, the steel must be below this temperature before welding continues.

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Why Choose Metro Welding Supply?

With a long history of selling industrial welding supplies in the greater Detroit Metropolitan area for over 70 years, Metro Welding Supply is a name that is synonymous with quality.

Metro Welding Supply provides only the best welding machines, welding supplies, industrial welding supplies, gas welding supplies, mig welding wire, tig welding equipment and supplies.

Metro Welding Supply delivers product throughout Metropolitan Detroit, including Sterling Heights & Ann Arbor, on a next day basis or same day basis if required.

If you would like any additional information on Metro Welding Supply’s services or products, please contact us today.

What is Tig Welding?

Tungsten inert gas (TIG) welding is the process of blending together reactive metals such as magnesium and aluminum. TIG welding is commonly used for both high quality and manual welding. Steel and aluminum are the two most widely used metals for TIG welding.

During the process of TIG welding, an arc is formed between a pointed tungsten electrode and the area to be welded. As a result of the gas shield, a clean weld is formed. This prevents oxidization from occurring.

The type of gas shielding typically used for TIG welding is argon, helium, or a combination of both. When combined, these two gases can ensure a higher welding speed and welding penetration. Argon is preferred because it is heavier than air and provides better coverage.

The filler rod is usually made from the same material as the base metal and is used for reinforcing joints and welding heavy metals.

Don’t forget to read our article about MIG Welding too, so you can spot the difference. And check back soon for more interesting articles from Metro Welding Supply. Don’t hesitate to contact us, should you have any questions.

What is Mig Welding?

For anyone new to the world of welding or just anyone who might be curious as to just what mig or tig welding (be sure to read that article too) is, here’s a relatively quick and painless explanation.

Basically, MIG (Metal Inert Gas), sometimes referred to as GMAW (Gas Metal Arc Welding) welding is the process of welding aluminum and other non-ferrous metals. Like TIG Welding, MIG Welding was originally developed during the 1940s.

The process involves a wire connected to a source of direct current which acts as an electrode that joins two pieces of metal, while it is continuously passed through a welding gun. The flow of an inert gas (originally Argon) is also passed through the welding gun at the same time as the wire electrode. The gas acts as a shield, keeping out air borne contaminants.

MIG Welding is ideal for softer metals. It also much quicker than traditional welding techniques.

Don’t forget to read our article about TIG Welding too, so you can spot the difference. And check back soon for more interesting articles from Metro Welding Supply. Don’t hesitate to contact us, should you have any questions.

Heavier Duty Equipment Is Best for Aluminum

While a little preheat is good, too much preheat can degrade the mechanical properties of the aluminum.

Many inexperienced aluminum welders use preheat as a crutch. Since equipment for welding aluminum needs to operate at higher capacities, many feel that preheat helps eliminate equipment limitations, but this is not the case. Aluminum has a low melting point, 1200° F compared to 2600° F - 2700° F for steel.

Because of this low melting point, many operators think they only need light duty equipment to weld the aluminum. But, the thermal conductivity of aluminum is five times that of steel, which means that the heat dissipates very quickly. For this reason, welding currents and voltages for welding aluminum are higher than they are for steel, so operators actually need heavier duty equipment for aluminum.