Welding Resources and Tips

5 Persistent Myths About Welding

In one form or another welders have had to deal with some pretty interesting attitudes towards the welding profession.

Some people think welding is a low-paying job. Others think there isn’t much diversity to being a welder. Even more interesting for women welders is this common remark: “Really? You’re a welder?” It seems no matter how much the profession has progressed, there are (at the very least) 5 persistent myths about welding.

 

Picture Credit: Jay Mann via Flickr

 

Welding is a low-paying profession

This myth suffers from the stigma surrounding all blue-collar jobs. Despite evidence to the contrary (see the Bureau of Labor Statistics (BLS) and Careers in Welding) there is still the idea that working with your hands earns less money than working with your head (although trade work requires working with both your hands and your head). Why is this stigma still around? As Joe Lamacchia, author of Blue Collar & Proud of It, stated in an interview with USA Today:

I think it was from the roaring '90s, the roaring lights of Wall Street, the computers, the cellphones — it was such an economic boom, it was unbelievable. It created all these jobs. I think we need to get back to basics. If you go to school, it doesn't mean you're going to make $150,000 a year. It's almost like we're producing too much of what we don't need and not enough of what we do need. I don't get it. I don't have a stigma toward my accountant. I need him and he needs me to pave and plow his parking lot.

Welding Fact or Fiction: Alternative Fuels Can’t Be Used for Welding and Cutting Steel

Introduction 

Alternative fuels, including propylene, propane, and natural gas, have earned a reputation for having a wide application. They have found their way into countless applications in manufacturing and metalworking, utilities, and general consumption. There has been one niche that hasn’t quite been penetrated by alternative fuels as much as it could be: welding and cutting steel. While the use of alternative fuels has been gaining traction with steel welders and cutters, it hasn’t reached its full potential yet due to one main misconception.

The Misconception 

The dominant fuel of choice on the part of steel welders has been acetylene. It’s preferred because of the heat it generates, which is necessary for quality welds and cuts. Very generally speaking, alternative fuels are not thought to be capable of generating the kind of heat that steel welders require and are accustomed to. This is a misconception, though, because while the nature of the heating properties of alternative fuels is different from that of acetylene, there are alternative fuels that can be as capable of welding and cutting steel as acetylene when used with the proper equipment. 

Properties of Acetylene vs. Alternative Fuels 

Acetylene has a higher burn velocity and releases most of its heat in the primary flame, concentrating its heat output and making it ideal for working with steel. Alternative fuels release heat in their secondary flame, which creates a more pervasive heat that spreads evenly through the base metals. Welders making the switch from acetylene to propane, propylene, or another alternative fuel will need to adapt their technique to work with the new fuels.

Why This Matters 

There’s a shortage of acetylene right now, due to a recent explosion in the plant that creates the majority of the nation’s calcium carbide supply - the key element in acetylene production. Welders who commonly use acetylene face the decision either to pay much higher prices and possible rationing of acetylene or to look into alternatives. 

Some Changes Required to Switch

To make the switch from acetylene to an alternative fuel, welders will need to make a few equipment changes. A new tank is the first requirement, as well as an appropriate regulator and a T hose (R and RM hoses will deteriorate over time, and may lead to an explosion). New heating and cutting tips may also be required, though for certain applications with some alternative fuels, just a thorough cleaning of the acetylene tip might suffice. And if the torch is the universal (or “spiral”) gas mixer type, it may work with alternative fuels without sacrificing efficiency or efficacy. To learn more about the specifics of switching from acetylene to an alternative fuel, read this article at BakersGas.com, How to Convert from Acetylene to an Alternative Fuel. And if you’ve decided to make the switch, don’t forget to check out all the top-quality products available at Baker’s Gas & Welding Supplies.

Photo Credit: Wikimedia Commons, via US DoD

Fact or Fiction: A Competitive Welding Equipment Market Equals Job Growth

In a recent article on BusinessWire.com the global welding market and its increasing growth is put on a spotlight. According to the article, the welding market is experiencing “strong growth” and will continue to experience growth well into 2017. So what exactly does this mean?

More welders, welding companies, and all those with an interest in welding are buying more welding products. Naturally you would assume more welding products being sold means that there are more welding jobs to perform, right? Which leads us to our Fact or Fiction question:

Does a competitive welding equipment market equal job growth?

Fact, but before you get excited let’s take a look at the numbers:

Welding products will haul in $16.3 billion this year and are expected to cross $17 billion in 2012.

Based on these rates sales of welding products are projected to go up to $21.9 billion by 2017, a compound annual growth rate (CAGR) or 5.2%.

In a job market as poor as what we’re experiencing, these numbers sound great. But let’s dive a little further into the details:

These totals are for the the global market, not just the United States. So we can’t assume that it’s the US at the top of sales.

A solid increase in demand for automated and robotic welding systems also account for the sales increase, which also amounts to job loss for certain sectors of the welding field.

There’s still a sliver of hope, even with the demand for robots.

According to this same report, the largest share of this market increase comes from consumable gas and protective equipment, which are anticipated to meet $10.9 billion in sales by 2012 and increase to 14.4 billion in 2017. Robots don’t need protective gear, so human workers are accounting for this share in the market increase.

At the end, this is all speculation. The numbers can be astounding, but if welding jobs are declining in your city then this report has little relevance to you. As I’ve pointed out in past blog posts, such as “Why Not Consider Freelance Welding?,” there are a few options to explore if you are a skilled welder with interest in starting a welding business. Depending on what kind of welding business you want to start, this report may be of huge interest to you. So let us know, what are your thoughts on this report?

 

If you want more information on this report, visit CompaniesAndMarkets.com.

Graph Picture Credit: Christian Ferrari

Welder Picture Credit: Michael Vroegop via Flickr

Electroslag Welding: Friend or Foe?

Almost all welders are familiar with the concept of electroslag welding, and with good reason, but we will discuss that in a bit. First of all, let's talk about the idea behind electroslag welding:

The Concept 

For thick materials, electroslag welding is perfect. This process is considered to be highly productive, especially for a single pass technique. During the process the electric arc is struck by the wire which is fed into the proper weld location, and then flux will be added. As flux is added, the molten slag will reach the tip of the electrode and extinguish the arc. The wire will be continuously fed through, and both the wire and tube will move along the workpiece. A copper shoe will be utilized during the process to keep the weld between the plates while the welding takes place. It is well known that this form of welding requires quite a bit of heat, and in some cases the copper shoe will actually be water cooled. Depending on the thickness of the material being welded, a higher voltage may be required. Because the arc is extinguished before the process begins, this cannot be considered a form of ARC welding.

The Origin

The concept and process of electroslag welding was patented by Robert K Hopkins, an American, in February of 1940. For those interested, the patent number is 2191481, the actual process was refined at the Paton Institute at Keive in the USSR throughout the 1940's, just before America became involved in what would become the Second World War. As with many technological developments of the time, electroslag welding was ultimately shown off at the world's fair where it was picked up by several automobile manufacturers. For instance, General Motors would use it to weld engine blocks, and it would even be used in the construction of certain buildings. One shining example would be the Bank of America building in San Francisco, along with the Security Pacific building in Los Angelas. A number of different buildings were used, and after the Northridge earthquake, a number of different buildings needed repair; the electroslage welding process was used to take care of these issues. It should be noted that there was not a single weld failure on any of the repair jobs, which is actually quite impressive in a new process.

The Banning of Electroslag Welding

In 1977 the Federal Highway Administration decided that it would take an active role in the use of electroslag welding on primary structural tension members. That is to say it was made illegal for use on bridges, and in many cases it's use on building supports was ceased as well. The ban stayed in place for nearly twenty years, and many were interested in the reasons behind this action.

The problem that the Federal Highway Administration noted was the fact that the amount of heat required to create a good weld would also produce course weld metal. The theory was that this would lead to serious fractures, and would at some point cause a structural collapse. The biggest problem however is a severe lack of understanding regarding the process which many believe was the reason for the banning in the first place.

A New Hope for Electroslag Welding

As of late, new methods of electroslag welding have been tried, and Narrow Gap Improved Electroslag Welding (NGI-ESW) was created with the hopes of meeting the toughness requirements of Zone 2 bridges. It should be noted that Zone 2 bridges are defined as those that open under friction, which generally means modern day drawbridges that are found on rivers with high traffic. It is understandable that these will require a tougher weld, and the NGI-ESW process has produced favorable results. One of the greatest advantages to NGI-ESW is the fact that there is no pre-heating required. The major disadvantage is that the process needs to be performed in the vertical-up position. That being the case, the maximum length of the weld is approximately four meters.

Whether or not there was ever truly a problem with electro-slag welding in the first place is anyone's guess. There are few, if any failures related to the process, though there are always those accidents that go unreported. Some failures may be attributed to welder incompetence, but in the end, only the law of physics can really make the determination.  

 

Fact or Fiction: Is Parkinson’s Disease A Potential Health Risk of Welding?

Because there is no concrete evidence to support either side, the answer depends on who you ask.

Picture Credit: EMSL via Flickr

 

A lawsuit currently in federal court may change the future of welding. Here are the details:

Former welder Ernest G. Solis is suing four welding rod makers alleging that Parkinson’s-like movement has resulted from working on their welding rods. Apparently when welding rods are burned their fumes contain the chemical manganese, and high exposure to that chemical can lead to problems such as shaking, tremors, and difficulty walking.

 

Why is one welder’s lawsuit such a big deal?

It’s not just one welder suing for this issue. This trial is only one out of 3,800 lawsuits, and the results of this case determine how the others are handled in court. This case has the potential to cost the welding industry millions of dollars and shape how welding fumes are dealt with in the future.

 

Should I be worried?

There are a few factors that are at play here, such as the varying work conditions for different welders. Some welders work in more confined spaces and with higher levels of manganese, therefor they are at a higher exposure risk than welders that don’t have these work settings.

Welding, generally speaking, should be taken seriously at all times. When it comes to welding fumes, the American Welding Society (AWS) Jefferson’s Welding Encyclopedia mentions these precautionary measures:

• Read, understand, and practice the safety instructions of the manufacturers handbook and stick to your employers safety standards.
• Make sure to keep your head out of the fumes
• Use plenty of ventilation and exhaust at the arc to keep fumes from your breathing area
• Wear the proper face, eye, ear, and body protection

 

This post isn’t meant to scare you away from such a rewarding trade. Just think of this as a fair warning that welding – while fun – should be taken seriously.

For more information on this case read Can welding fumes cause Parkinson’s? at MSNBC.com.