Welding Technology

  A resistance weld process monitoring 1. How can I find the cause of inconsistent resistance welding results? Process consistency is a common challenge in resistance welding. A number of things can go wrong, all caused by variations in one or more of these areas: equipment performance, material properties, and process settings. To find the culprit, start by recording weld process parameters with a weld monitor and examining the results. An experienced, well-trained operator can detect welding problems and make educated guesses about their causes, but without the data from a weld monitor, that operator is largely running blind. 2. What process parameters can be measured by a weld monitor? A resistance weld monitor can measure electric current during the weld, voltage between electrodes, electrode force, and electrode movement. Basic models output a numeric aggregated value (minimum or maximum) for one or more parameters. More advanced monitors can capture and analyze the entire hig...

  How to attract a new generation of welders with advanced technologies The welder shortage has plagued manufacturers and fabricators for years. A global pandemic, a shifting job market, and generational trends only have exacerbated the matter. On the one hand, many experienced welders—those tried-and-true pros who have seen it all—edge increasingly closer to retirement or, because of burnout or disenchantment, embark on entirely new careers. On the other hand, as the manufacturing sector knows all too well, millennials and Generation Z (and even Generation Alpha) have an entirely different perspective on working in production or manual jobs. Despite the staffing doom and gloom, strategies exist that can help any welding or manufacturing team looking to hire skilled welders or the few-and-far-between newcomers to the art of welding. It starts with technology. Needless to say, it takes a multipronged approach to attract and retain top talent, regardless of a candidate’s age. However...

  Jim's Cover Pass: A look ahead in the welding industry In my last column, I revealed one of the most interesting and frequently asked questions I receive. As for the second most frequently asked question I receive:  What do you see for the future of the welding industry? This is a tough one. None of us has a crystal ball that lets us see into the future. However, there are a few things on the horizon that may cause some major changes in our industry. The first is education. After many years of talking about it, I think we are starting to make some headway in career and technical education becoming an acceptable alternative to the four-year university track. With continued emphasis on this in the secondary schools and a deeper understanding of the career potential by both counselors and parents, we could see growth in the potential workforce. In this same manner, the welding industry as a whole should see a major increase in earning potential. The mindset of industry ma...

  Additive Manufacturing is Propelling the Next Generation of Space Exploration What do I think about space exploration? If you ask me that question and get me started on that topic, I probably won’t be able to stop. Since the new space race has begun, we are starting to see “new space” companies pop up that are basically tech startups: highly motivated, enthusiastic, driven individuals who are committed to their mission and will do “what’s right” to achieve their goals. Additive manufacturing (AM), or 3D printing, is a tool they can use to help achieve their goals. For metallic components on spacecraft or even on the launch pad, AM is, simply put, propelling the next generation of space exploration. In the last few years, we have seen tremendous success in the public and private space exploration industry. The legendary William Shatner (Captain Kirk of “Star Trek” fame) took a ride on Blue Origin’s New Shepard vehicle when he was 90, becoming the oldest person to go to space. Spac...