Scottie Smith, 2018 Teacher of The Year

THE REAL WORLD FOR WELDING PROFESSIONALS July/August 2018
Formerly Practical Welding Today
Breaking down
aluminum GTAW
Addressing common
problems in wire welding
Scottie Smith,
2018 Teacher
of the Year
An official publication of the

Fabricators & Manufacturers
Association, International®
JulAug18Welder.indd 1 7/9/18 9:38 AM

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THE
CONTENTS
®
July/August 2018 / Vol. 1 No. 6
FEATURES DEPARTMENTS
14 24 6
COVER STORY SEMIAUTOMATIC WELDING UNDER THE HOOD
Transforming nonwelders into skilled Identifying and addressing common
pipe welders problems in wire welding 8
Scottie Smith, a welding instructor at One wrong move can jeopardize weld CALENDAR
Northwest Florida State College, is The quality. Whether you’re solid-wire welding
WELDER’s 2018 Teacher of the Year. or flux-cored wire welding, following the
(Cover photo courtesy of Northwest proper procedure should help you avoid 9
Florida State College, Niceville, Fla.) costly mistakes. INDUSTRY NEWS
20 28 36
GTAW Q&A WELDING HACKS
How to weld aluminum with GTAW Family, friendship, and metal An angle grinder hanger to keep your shop
Whether the goal is increasing fabricating organized; a jig for cutting long bands
penetration or achieving the stack-of- Longtime friends who opened a custom from coil or sheet
dimes appearance, these tips can help job shop in Monroeville, Ind., discuss their
you achieve success when welding
aluminum with GTAW, regardless of
journey as business owners. 38
your experience level. PLAYING WITH FIRE
32 Josh Welton writes of his experience
FINISHING learning from past instructors and co-
Cutting, grinding, and finishing workers and urges readers to always keep
an open mind and continue striving to
You shouldn’t use the same abrasive learn more.
product for every cutting, grinding, and
finishing job. Consider these seven tips
for best results. 40
ALUMINUM WORKSHOP
Frank Armao explains why some
alloys in the 7XXX and 2XXX families
are incompatible with fusion welding
processes.
42
CONSUMABLES CORNER
The Consumables Corner team counsels a
fabricator new to aluminum welding.
44
PRODUCT NEWS
49
CLASSIFIED ADVERTISING
49
ADVERTISERS INDEX
50
JIM’S COVER PASS
A reader deciding between welding school
and going to work turns to Jim Mosman
for advice.
4 July/August 2018 The WELDER

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UNDER THE HOOD
Amanda Carlson
Editor, The WELDER®
amandac@thefabricator.com
More than just a welding teacher

One of my favorite articles to put together each year is the Teacher of the Year
feature. Since 2012 we have asked you, the reader, to nominate welding instructors
who go above and beyond in service of their students, the community, and their
program. While that description is certainly open to interpretation, we’ve never been
disappointed by the quality of your nominations.
This year was no different. Our Teacher of the Year for 2018 is Scottie Smith, a
welding instructor at Northwest Florida State College, Niceville, Fla. You can read
his story, “Transforming nonwelders into skilled pipe welders,” on p. 14 of this issue.
He’s a Navy veteran, a former business owner, and spent many years of his welding
career on the road as a construction pipe welder.
When I flew down to Florida in May to meet him, my first impression was that he
talked fast, he talked loud, and he had a ton of energy. He’s a lot to try and take in at
first. But it became very clear throughout our conversation that he is at home when
he is teaching. His eyes light up, he talks a little louder, a little faster, and a little more
with his hands. He’s most animated when he’s talking about students, both former
and current. Their successes are a point of pride for him.
I’m not sure he’d ever admit to this because it might tarnish his reputation for
being hard-nosed, but I think for as proud as he is to see his students thriving in
the real world, he gets an even bigger high from the fact that many of them enjoy
sharing the journey with him even after they’re long gone. They call him from the
road, invite him to weddings, or stop in just to say hi and to talk shop. He teaches
them a life-altering skill, but he also lends his guidance, support, mentorship, and
friendship.
I think what students like about Smith is that he doesn’t adjust the bar for anyone
regardless of their gender, age, or life experience. He’s created a culture founded on
accountability, responsibility, commitment, and trust. Trust in one’s self and trust in
Smith—that he’s going to deliver on his promise to teach you how to be a dynamite
pipe welder. All he asks is that you lower your walls enough to trust his cues and
make the commitment to put your training ahead of everything but your religion and
your family.
If you can do those things, he’ll do the rest.
@TheWELDERmag @theweldermagazine

CALENDAR OF EVENTS
THE
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GOLF4MFG NBT Open Manufacturing DaySM

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Fabricators & Manufacturers Assn. Intl.
5 North America
NAM
August October
888-394-4362 | www.fmanet.org 202-637-3121 | www.mfgday.com
Pipe & Tube Memphis AWS Detroit Sheet Metal Welding
17-19 Memphis
Fabricators & Manufacturers Assn. 17-18 Conference
Livonia, Mich.
September 888-394-4362 | www.fmanet.org October AWS
586-466-7070 | www.awsdetroit.org
The FABRICATOR’s Technology Summit FABTECH®

2-3 Huntersville, N.C.
Fabricators & Manufacturers Assn.
6-8 Atlanta
FMA, SME, PMA, AWS, CCAI
October November
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The WELDER staff FMA officers & directors Carlos Mendizabal-Perez, Industrias Selbor SA de CV
President & CEO, FMA Edward Youdell Chairman of the Board Lyle Menke, Peddinghaus Corp. Jay Phillips, Valley Iron Inc.
Group Publisher Dave Brambert First Vice Chairman William “Jeff” Jeffery, IRMCO Sarah Richards, Jones Metal Inc.
Editor-in-Chief Dan Davis Second Vice Chairman Gregg Simpson, Ohio Laser LLC James Rogowski, TRUMPF Inc.
Secretary/Treasurer Bill Isaac, MC Machinery Systems/Mitsubishi Laser Lori Tapani, Wyoming Machine Inc.
THE WELDER Editor Amanda Carlson
Immediate Past Chairman of the Board Vivek Gupta, Lisa Wertzbaugher, Superior Tube Products
Contributing Editor Amy Nickel Texas ProFab Corp.
Senior Copy Editor Teresa Chartos President & CEO Edward Youdell,
Fabricators & Manufacturers Association Intl.
Graphic Designers Jennifer Paulson, Margaret Clark, Directors
Mary Mincemoyer, Janell Drolsum John Anton, The Tube Group Inc.
Publication Coordinator Holly Lipper The WELDER Editorial Advisory Committee
R. Bruce Benedict, Production Tube Cutting Inc.
James R. (Rob) Bohn Jr., Nema Enclosures Manufacturing Corp. Paul Cameron, Element Materials Technology-St. Paul
Director of Circulation Kim Bottomley
Andy Gross, Alliance Steel LLC Daniel Galiher, Tower Intl.
Circulation Manager Brenda Wilson
Rick Hargrove, Steel & Pipe Supply Co. Inc., Storage & Processors Warren Long, Briggs & Stratton Corp.
Data Verification Specialist Rhonda Fletcher
Brian Havlovic, Kawasaki Motors Mfg. Corp. USA James Mosman, Odessa College
Senior Fulfillment Specialist Anna Peacock
Jason Hillenbrand, Amada America Inc. Allen Parsons, Austal
Web Content Manager Vicki Bell
Phil Kooima, Kooima Co. Daniel Turner, Yuba College
Multimedia Specialist Sherry Young
Senior Web Manager Mike Owens
Statement of Policy
As a publication of the Fabricators & Manufacturers Association International, The WELDER recognizes the need and
The WELDER advertising sales importance of disseminating information about modern metal welding and joining techniques, machinery, tooling, and
Associate Publisher Jim Gorzek, jimg@thefabricator.com management concepts for the metalworking professional. The policy of the publisher and this journal is to be nonpartisan,
favoring no one product or company. The representations of facts and opinions expressed in the articles are those of the
Senior Account Representatives author and are not necessarily endorsed by the publisher and this journal. By including information on new products, new
literature, news of the industry, articles, etc., this impartiality is strived for and extends to the mention of trade names. Unless
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product identification makes the reference unavoidable, the generic name is used. We acknowledge that on occasion there
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publishers reserve the right to refuse advertising they deem inappropriate for publication in The WELDER, including ads for
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GA, MD, OH, and International advertising rates in Section 156. Consult SRDS or our current rate card for full rates and data.
Phil Arndt, phila@thefabricator.com Publications of FMA Communications Inc. maintain a policy of keeping editorial and advertising separate to ensure editorial
AR, AZ, CA, CO, ID, KS, LA, MO, MS, MT, integrity that most benefits our readership. Editorial content, including feature articles and press releases, is determined
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Editorial is free-of-charge, subject to space availability, and open to all interested parties that submit items meeting our
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IA, IN, MI, MN, NE, WI, and Canada
Note: Some photographs printed in this publication may be taken with safety equipment removed for photographic purposes.
Michael Scott, michaels@thefabricator.com However, in actual operation, it is recommended that correct safety procedures and equipment be utilized.
IL, NC, SC
John Mathews, johnm@thefabricator.com FMA’s Certified Education Centers
Classified Advertising (U.S., Canada, and International) FMA Certified Education Centers (CEC) are community and technical colleges, trade schools, and universities that specialize
Director of Accounting Bob Young in training adults for careers in the metal forming, fabricating, processing, and machining sectors. They offer coursework
for local students year-round and serve as host locations for many types of FMA professional development programs as
Accounts Receivable Mary Simons requested. A council of representative members convene six times a year to plan and execute special programs on worker
training for educators and human resource managers from companies of all sizes.
Contact The WELDER
To learn more about FMA’s CEC program and view a list of the current member schools,
2135 Point Blvd., Elgin, IL 60123 visit www.fmanet.org/involvement/certified- education-centers/.
Phone: 815-399-8700 • Fax: 847-844-1270
To discover how your local community or technical college can become a member,
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call 888-394-4362 or send an e-mail to info@fmanet.org.
A PUBLICATION OF BUSINESS PUBLICATIONS

FMA COMMUNICATIONS INC. AUDIT OF CIRCULATION

INDUSTRY NEWS
LZH, partners develop laser welding process for joining

3-D structures of steel, aluminum
beam welding process is a 3-D scanner partners remain safely connected.

optic, newly developed by TRUMPF LZH, VW, and partners inpro Inno-
Laser GmbH. With this optic, complex, vationsgesellschaft für fortgeschrittene
3-D seam geometries are possible even Produktionssysteme in der Fahrzeugin-
on large structures. Therefore, the pro- dustrie mbH, Precitec GmbH & Co.
cess is suitable for car body construc- KG, MATFEM Partnerschaft Dr. Gese
tion and can be used as an alternative & Oberhofer, Lunovo GmbH, Scherdel
Laser Zentrum Hannover e.V. (LZH), to complex robotic movements. Marienberg GmbH, InfraTec GmbH,
within the LaserLeichter project, has The weld joint achieves a shear ten- Brandenburgische Technische Univer-
developed a laser welding process for sile strength of about 67 percent of the sität Cottbus-Senftenberg, and the
quick, safe joining of 3-D structures aluminum alloy. The parallel arrange- Fraunhofer-Institut für Werkstoff- und
made of steel and aluminum, such as ment of the three welds can increase Strahltechnik IWS worked together
lightweight steel-aluminum composite this percentage to about 95. under the coordination of Robert Bosch
components used in automobiles. The process was developed for GmbH. Associated partners were
To optimize the joining of mixed battery cases of electric cars, seat TRUMPF Laser GmbH, Astor Schnei-
compounds for series production in the structures, and car body parts. dwerkzeuge GmbH, ThyssenKrupp
automotive industry, the scientists at Volkswagen AG has tested the Steel Europe AG, Bond-Laminates
LZH have developed processes for join- validation components for car body GmbH, and Hydro Extrusion Offenburg
ing two- and three-sheet metal joints applications. The joined mixed GmbH. The LaserLeichter project was
with high welding speeds of up to 23 compounds have an advantageous funded by the Federal Ministry of Edu-
FPM. The basis for the remote laser crash behavior, since the joining cation and Research.
ESAB GTAW/SMAW inverter receives Red Dot Award

for product design
uct design in the Industrial Equipment, The 37-lb. inverter features an
Machinery, and Automation category. extreme power-to-weight ratio in a
For the 2018 Red Dot Awards, compact format of 12.6 by 7.8 by 18.11
designers and manufacturers from 59 in. It runs 300 amps at 40 percent duty
countries submitted more than 6,300 cycle with leads and welding cables up
objects to the competition. True to the to 110 yards and has excellent multi-
motto “In search of good design and voltage capabilities, says the company.
innovation,” a jury comprising roughly The unit connects to 230-V, one-phase
40 members assessed the products in- power and 230- to 480-V, three-phase
ESAB Welding & Cutting Products dividually based on the original. Judg- power (both ±10 percent) with auto-
has announced that its Renegade™ ET ing criteria includes level of innovation, sensing functionality and no rewiring
300iP DC GTAW/SMAW inverter has functionality, formal quality, ergonom- required.
received the Red Dot Award for prod- ics, and durability.
Hypertherm named one of America’s best employers by Forbes

Hanover, N.H.-based Hypertherm, companies. the likelihood of recommending
a manufacturer of industrial cutting To create the list, market research their employer to others, in addition
systems and software, has been company Statista surveyed 30,000 to answering questions related to
selected as a Forbes Magazine Americans working for both large working conditions, salary, potential
America’s Best honoree, earning the and midsize employers. Surveys were for development, and company image.
No. 30 spot on its list of the 500 Best anonymous, allowing participants The final list ranks the employers
Midsize Employers and the No. 2 spot to openly share their opinions. receiving the most recommendations.
among engineering and manufacturing Respondents were asked to rate
The WELDER July/August 2018 9

INDUSTRY NEWS
Walter Surface Technologies acquires Blackstone supply agreement from Sundisc Abrasives
Montreal-based Walter Surface Technologies has announced
the acquisition of the Fastenal® Blackstone® supply agree-
ment and all related inventory from Sundisc Abrasives USA
LLC. With this agreement, Walter becomes one of Fastenal’s
private label suppliers.
Blackstone is one of Fastenal’s brands of abrasives and
welding consumables.
Weiler partners with Workshops for Warriors to launch fundraising campaign

Weiler Abrasives Group, nonprofit school that trains, training programs at the products to meet the needs
Cresco, Pa., a provider of certifies, and helps place nonprofit trade school, as of each incoming class every
abrasives, power brushes, veterans, wounded warriors, well as contribute to semester.
and maintenance products and transitioning service long-term growth of the The company will contin-
for surface conditioning, members into advanced organization. ue offering this support and
has launched a national manufacturing careers. The company has been will promote the fundraising
fundraising campaign, Weiler donated $25,000 providing Workshops for campaign at tradeshows and
“Leading A Warriors’ to kick off the year-long Warriors with in-kind support with partnership-branded
Charge,” in partnership with campaign that will support since 2014, supplying abra- product packaging.
Workshops for Warriors®, a machining and welding sive and safety
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INDUSTRY NEWS
Miller donates introduce the students to • June 18-22: Silly Boys, • July 30-Aug. 3:
$10,000 to NBT the high-tech career choices Manufacturing is for Girls— FabCamp—Madison Area
foundation’s available to them in today’s Milwaukee Area Technical Technical College, Fort
advanced manufacturing College, Milwaukee Atkinson
manufacturing camp
industry. This summer NBT
grant program • June 18-21: Nuts, Bolts • Aug. 6-10: Power of
will support a record number
& Thingamajigs Summer Manufacturing—Fox Valley
Arc welding products manu- of 90 camps across the U.S.
Camp—Gateway Technical Technical College, Appleton
facturer Miller Electric Mfg. Miller’s gift will support
Camp, Sturtevant
Co. LLC, Appleton, Wis., is the following summer • Aug. 6-9: Welding and
supporting 12 2018 sum- 2018 camps throughout • July 9-13: Metal Form & Fabrication—Northeast
mer manufacturing camps Wisconsin: Fusion—Fox Valley Technical Wisconsin Technical
in Wisconsin with a $10,000 College, Oshkosh College, Green Bay
donation to Nuts, Bolts & • June 11-15: Tech Girls—
• July 16-20: FUN with Since 2004 NBT has
Thingamajigs® (NBT), the Lakeshore Tech College,
Torches (Welding awarded more than
Foundation of the Fab- Cleveland
FUNdamentals)—Madison $750,000 in grants to trade
ricators & Manufacturers Area Technical College, schools and community and
• June 11-15: Toolin’ It
Association Intl. (FMA). The Portage technical colleges to host
Summer Manufacturing
donation will allow about summer camps that will lead
Camp—Moraine Park Tech- • July 16-20: Girls in the
200 students, aged 12 to to careers in manufacturing.
nical College, West Bend Shop—Fox Valley Technical
16, to be introduced to the For more information, visit
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www.nutsandbolts
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The one- or two-week- Manufacture—Northcentral Form & Fusion—Fox Valley
long summer camps Technical College, Wausau Technical College, Oshkosh

INDUSTRY NEWS
Weldcote Metals adds to its ownership group. Zika 25 years of experience in CK Power acquires
ZWC Holdings to Group is a global provider the industrial welding tool Consolidated Machine
ownership group of welding consumables and marketplace. Weldcote’s & Welding
equipment. Bill Roland, founding CEO
CK Power, a manufacturer
Charlotte, N.C.-based Zika Group has ap- and current president, and
of off-highway engines and
Weldcote Metals Inc., a pointed Joe O’Mera, former John Pandorf, co-founder
power generators based in
manufacturer and wholesaler president of CGW, Camel and CFO, will continue in
St. Louis, has acquired Con-
of welding supplies, has Grinding Wheels, as CEO their capacity as company
solidated Machine & Weld-
announced the addition of of Weldcote Metals and owners and members of the
ing (CM&W), Hannibal, Mo.
ZWC Holdings Inc., con- as part of the ownership management team.
CM&W has kept its name
trolled by Zika Group Ltd., group. He has more than
and is called a division of
CK Power. The company
offers laser cutting, produc-
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Weld Mold Co., Brighton,
Mich., has received the ASM
Historical Landmark Award
for 2017 from ASM Intl. The
company received the award
for developing and innovat-
ing the flood welding pro-
cess for weld die repair. Matt
Kiilunen (1905-1990), who
founded Weld Mold in 1945,
was personally responsible
for innovating the process.
The Historical Landmarks
designation recognizes sites
and events that have played
a prominent role in the
discovery, development, and
growth of metals, metal-
working, and all engineered
metals.

INDUSTRY NEWS
Bluco launches Advance Welding Flex-N-Gate to Retired Hobart

redesigned website receives Nadcap expand in Texas Brothers manager
Bluco Corp., Naperville, Ill., Merit status for Automotive supplier inducted into
has announced the redesign welding and brazing Flex-N-Gate Corp., based in engineering academy
of www.bluco.com. It fea- Advance Welding, located Urbana, Ill., has announced Hobart Brothers LLC, a
tures improved navigation, in Springfield, Mass., has plans to expand into a new, filler metal manufacturer in
as well as photography and been awarded Nadcap Merit 430,188-sq.-ft. manufactur- Troy, Ohio, has announced
product descriptions, video status for fusion welding, ing plant in Grand Prairie, that Dean Phillips, former
and literature libraries, and brazing (torch/induction), Texas, which will supply auto manager of welding
case studies. and resistance welding. parts directly to General engineering, is one of
The new Bluco Blog While the company has held Motors. 31 engineering alumni
features relevant news and annual Nadcap accreditation The $175 million project inducted into LeTourneau
information about modular since 2006, this special rec- includes about a $70 million University’s inaugural
fixturing. Guided instruc- ognition grants accreditation investment in new equip- Academy of Engineering and
tions show visitors how to through July 31, 2020. ment for injection mold- Engineering Technology.
upload CAD documents The firm, marking 40 ing, metal stamping, and The academy is a hall of
and start the quotation years of serving the aero- automated robotic metal fame that recognizes the
process. A portal allows cur- space, defense, marine, and welding. It also includes an career achievements and in-
rent customers to schedule power-generation industries, addition of about 50,000 sq. dustry influence of outstand-
training, download the CAD also recently achieved ISO ft. to accommodate offices, ing alumni of LeTourneau’s
database, and view pricing 9001:2015 and AS9100D break rooms, lab areas, and School of Engineering and
documents. registration. utilities. Engineering Technology.

COVER STORY
Transforming nonwelders
into skilled pipe welders
Meet Scottie Smith, the 2018 Teacher of the Year
By Amanda Carlson
It’s a typical May evening in Niceville,

Fla.—sunny, humid, with a temperature in
the mid-80s. Seated next to the window
at a cozy waterside restaurant are Scottie
Smith and his wife Kim. Not long after the
appetizer arrived, Smith reached down
into his pocket, pulled out his phone, and
looked at his screen before putting it back
into his pocket. A few minutes later he re-
peated this process. Kim didn’t even have
to ask who it was or what they wanted—
she already knew.
“It’s one of his students,” she said.
“They call him every day.”
“She’s right,” Smith said.
For someone who on the first day of
each semester at Northwest Florida State
College reminds his students that he’s
their welding instructor, not their friend or
therapist, he has an awful lot of students
who call him. “A lot of them are on the
road working jobs and they want to tell
me about them or run something by me,”
Smith explained.
Who can blame them? After all, Smith
has taught his students valuable life les-
sons such as leadership, accountability,
work ethic, and responsibility. And if that’s
not enough, he’s taught them a craft that
provides an excellent living. Not bad
considering the fact that the college didn’t
even have a welding program before 2013.
“CAN I MAKE IT ON MY OWN?”

Smith has been involved with welding in
one way or another since he could walk
thanks to his father, who taught welding at
Southern Union State Community College
in Opelika, Ala. After high school Smith en-
Scottie Smith, welding instructor at Northwest Florida rolled at a community college, but found
State College, is the 2018 Teacher of the Year. Smith has
grit, determination, and a proven track record of success. that his interests didn’t involve academics.

COVER STORY
Given the choice by his father to either continue his

education or get a job, Smith chose neither.
“I actually thought to myself, ‘Well, I’ll show him.
I’m going to join the Navy.’ When I told my dad, he
said, ‘Do you need a ride to the recruiter?’”
He became a welder while in the Navy and
worked on nuclear fast attack submarines and
amphibious watercraft. After six years of service,
Smith became a firefighter and went back to school
at Southern Union State Community College to earn
an associate degree and learn more about welding
from his dad. From there he went out on the road
as a contract welder chasing construction jobs. He
met and married Kim and eventually went back to
Alabama and opened his own welding and fabrica-
Smith’s program places an emphasis on construction pipe welding.
tion company.
Upon successfully completing the program, students are able to
Business was good until the recession in 2008. weld according to AWS D1.1 structural code and ASME B31.1
He sold the business and began teaching at South- boiler and pressure vessel welding code. From there they are
ern Union in 2009 after his father had retired. It was qualified for jobs that pay around $30 an hour.
an honor to step into his dad’s shoes—the man he
refers to as his hero—but it was also daunting. His
father was well-known and highly respected in weld-
ing circles and was even the recipient of the Howard
E. Adkins Instructor Membership Award from the
American Welding Society (AWS) in 1999. Scot-
tie carried on his father’s legacy, which was tough
considering how influential his dad was at the school
and with current and former students.
After about two years Smith was presented with
the opportunity to take over the program at West
Georgia Technical College in LaGrange, Ga. The in-
structor there had retired and the program was dying.
It had only nine or 10 students during the day and
roughly six at night. Smith saw it as a chance to start
fresh and make his own way in the world of teaching. Scarlett Quesenberry, 18, lays a weld pass on a pipe with GTAW.
“At Southern Union I was in my dad’s shadow.

Everybody knew him, and I wanted to prove that I “One guy worked second shift and he came
could do it on my own,” he explained. to me a little upset and said, ‘I work second shift.
It was a good experience that allowed him to I don’t get off until like 10 or 11 p.m., so I’m not
cut his teeth and figure out what kind of teacher going to be coming in to class until 9 a.m. because
he wanted to be. He found early on that he wasn’t I need to get some sleep.’ I told him again that we
going to be someone who adjusted the bar to make start at 7 a.m. I said, ‘You’re going to come in every
life easy for anyone. day on time or you can leave.’ He argued with me
“I went in on that first day and I said, ‘I’m not and said he needed a special arrangement. I told
your friend, your buddy, or your pal. I’m your weld- him no and to get his butt up and come in to work
ing instructor. Everybody’s got personal issues and or go home. It doesn’t matter to me because I’m
problems. Don’t tell them to me, I’m not your thera- here. Well, he went home.”
pist. I’m going to teach you how to weld, so leave The guys who bought into Smith’s philosophy
your personal problems at home. If you do that I will excelled, so eventually the program did too.
guarantee you that I’ll do everything I can to teach “We expanded to 20 weld booths and we had 18
you everything I know about welding.’” or so students in the daytime and 12 to 15 at night.
From day 1 Smith demanded total commitment We even hired a second instructor for the nighttime.
to the welding program, and that hard-line philoso- I’d taken a program that was pretty much done and
phy didn’t sit well with everyone. brought it back to life, and that felt good.”

COVER STORY
The Welder’s Playground is Smith’s

brainchild and was constructed by his
students. This apparatus gives them the
opportunity to get out of the booth and
work and weld in situations that are more
realistic. For example, instead of cutting
a piece of pipe on the flame beveler or
band saw, students must bevel the pipe
by hand using a portable band saw or a
saddle beveler.
STARTING FROM SCRATCH

Since the program was new, Smith had to do every-
thing, from choosing the building and constructing
the weld booths to designing a curriculum. It was
a tall order, so he kept things small and went with
what he knew. He chose a small building that, at the
time, was occupied by the fire department and EMT
programs. Once they relocated into a new building,
Smith had a place all his own. He constructed 15
welding booths pretty much by himself. Other than
the weld booths, the building was bare bones. It
didn’t even have a bathroom.
And he chose a focus—pipe welding. It’s where
a majority of his experience is and he knew that it
would give students the best chance to become
employable, valuable welders who could make a
When presented with a new opportunity to start good living traveling across the country and making
his own welding program from scratch, Smith had the a lot of money quickly.
confidence in his abilities necessary for the challenge. “I know pipe welding, specifically construction
He accepted the position of weld instructor at pipe welding, which is what I did. It’s where the most
Northwest Florida State College in Niceville, Fla., in job opportunities are, and that’s where they’re mak-
May 2013. The school was one of five in southern ing the most money. Look, if my students are going
Alabama and the Florida Panhandle to receive a $10 to spend 18 months with me, then they need to be
million grant, and Northwest Florida State College, compensated as highly as possible.”
along with two other schools, intended to use the His first class walked through the doors in August
money to start welding programs. 2013. With nothing or no one to compare it to, the
He saw it as a chance to really go out on his own. students in that first class who bought in excelled,
“Nobody knew me here. It was the perfect place and they were being hired by companies that paid
for me to figure out, Can I do it on my own without well. They were prepared and disciplined. Word got
my dad’s shadow propping me up?” out, and more prospective students came.

COVER STORY
In similar fashion, The Sandlot allows students to weld in conditions and ori-
entations that are more true to life than what they can experience in a booth.
The welding program Smith designed comprises half is 750 hours. We’re not a credit hour program.
four semesters, two in the fall, one in the spring, and We’re all about contact hours. If you miss more than
one in the summer. In their first fall semester, it’s all 10 percent of your scheduled class time, you fail that
shielded metal arc welding (SMAW). In the spring class.”
semester students learn gas metal arc welding The program grew in popularity so quickly that
(GMAW), flux-cored arc welding (FCAW), and gas they decided to admit students not on a first-come/
tungsten arc welding (GTAW) of plate. Summer se- first-served basis, but instead on a point system.
mesters are reserved for SMAW of pipe. In their final Completing the Free Application for Student Aid
fall semester, the focus is reserved for GTAW/SMAW (FAFSA) form, having documentation of previous
combo pipe welding and welding on specialty pipe, welding experience, and passing a drug test are
like stainless steel. It’s a lot of material in a short each worth 20 points. Being a veteran or a depen-
amount of time. dent of a veteran, visiting the Okaloosa Career-
But it’s worth it. Students who pass rigorous Source Center as well as attending a mandatory
training are able to weld according to the AWS D1.1 orientation are each worth 10 points. And success-
structural code and ASME B31.1 boiler and pressure fully completing general education courses at the
vessel welding code. college with a C or higher are worth points too.
It goes without saying, then, that the culture re- The more credits completed, the more points the
volves around structure. It’s what Smith learned from student gets.
his father and his time in the Navy, and it’s how he “Honestly, it’s kind of a screening process. And
transformed the welding program at West Georgia some of this is a pain in the butt to have to do as
Tech. The booths are neat, tidy, and organized. The much stuff. But by doing this, the students I get are
toolroom is well-kept with everything in its place serious. Very rarely do I have somebody that just
and a clear system for checking out and returning wants to come in and play around,” Smith said.
equipment. In 2017 he added 15 more welding booths,
And attendance is mandatory. bathrooms, and a classroom. Students collaborated
“The entire program consists of 1,800 contact on constructing The Sandlot and The Welder’s
hours. The first half is 1,050 hours and the second Playground. Both installations, located just outside

COVER STORY
the shop, allow welders to get out of the booth schools across the country and ours is one of them.
and into the elements and orientations that they’ll I’ll notify them when I have a graduating class, like
experience on the job. in December; they’ll fly an inspector and someone
To ensure students learn how to perform under from HR out here; and then we’ll administer a weld
pressure, they must take a weld test every Friday. test and an evaluation. Then they’ll do an on-site
“It’s set up just like a weld certification test. I interview for the ones that pass the test and they’ll
don’t help them with anything. On that day, I’m the pick who they want to hire.”
inspector. I tell them what I want, the points where
I’ll check it, and that’s it. If they mess up, it is what RAISING THE BAR
it is. They have to learn that when they go for a job, Smith has stuck to the philosophy he honed at West
they’ll get only one shot to do it right.” Georgia Tech. He doesn’t lower the bar to accom-
Students are so well-prepared that many hire modate anyone or give students a false sense of
on with companies during the break between the confidence. The bar is where it’s at for a reason, and
spring and summer terms just to make extra money it’s up to each student to do the work to meet or
and gain valuable work experience. Their successes exceed it.
have garnered the attention of big major compa- “I believe that people will rise to the standard
nies, including JV Industrial Corp. (JVIC), a specialty you set. If you demand something tough, most
welding firm with locations out West. people will work to achieve it. If we don’t have high
“They have a finishing welding school. They expectations, we’re letting these students off easy.
look for new talent to train to their specifications By the time they come to us, they’re 18 years old.
and their welding processes for the oil refineries They’re adults. It’s our job to give them the informa-
and chemical plants. So they work with about three tion they need and to make sure they understand
Scarlett Quesenberry said she fell in love with Alex “AD” Dickon always liked working with his Joel Jaroch, 19, was a little intimidated by
pipe welding within the first couple of days of hands and realized welding was his calling after Smith’s hardline stance on day 1. But he
class. One thing that has stood out to her is the enrolling in the welding program at Northwest recognizes now that tough persona is just
fact that Smith doesn’t treat her any differently Florida State College. He credits Smith for Smith’s way of setting a high standard to
than anyone else. While she’s in class, she’s a teaching him a craft that has opened doors to adequately prepare students to excel in the
welder—no better or worse than anyone else. traveling the country and making a good living. real world.

COVER STORY
the information. From there we must hold them people welding sur-
accountable for it. prised even Smith, “I KNOW PIPE WELDING,
“This welding program is a life-altering event. who “complains”
When you’re done with this, if you get a job in weld- that he has to be at SPECIFICALLY CONSTRUCTION
ing, you’re going to be going from making $300 the shop during his
or $400 a week to $2,500. You’ll have a different break. He’d be there PIPE WELDING, WHICH IS WHAT
lifestyle, and you need to be ready for that, period. anyway. He knows I DID. IT’S WHERE THE MOST
I tell them that their top three priorities for the it, his wife knows
next 18 months are their religion, their family, and it, and his students JOB OPPORTUNITIES ARE,
this program. If their current job interferes with the know it. They know
welding program, they need to get a different job. that in real life there AND THAT’S WHERE THEY’RE
This program can change your life and we get real are no breaks. MAKING THE MOST MONEY.
results.” While sitting at
Current student Alex Dickon—Smith calls him his desk, Smith’s LOOK, IF MY STUDENTS ARE
AD for short—had never welded before last August. phone buzzed. It
This past May he was working a shutdown job at a was a student. He GOING TO SPEND 18 MONTHS
concrete plant in Miami, reinforcing and repairing wanted to know if WITH ME, THEN THEY NEED TO
things with SMAW. He worked 12-hour shifts for he could come up
seven days a week and banked around $2,600 per and weld. Of course, BE COMPENSATED AS HIGHLY
week. He never imagined something like this was Smith said.
possible a year earlier. “I mean, they’re AS POSSIBLE.”—Scottie Smith
“I was tired of where I was with my life before, not my kids. But I
and I wanted to change. I knew I liked working with need to check on
my hands. I worked at a bar and I would just talk to them. What’s going on? How’s it going with y’all?
people and everybody, for some reason, said, ‘You What’s your foreman like?”
should go for welding.’ So my buddy and I looked That tough guy that students see on day 1 melts
into it and finally did it. It’s been the best change away over the course of the program. They stop
that I could have made,” AD explained. seeing him as a drill sergeant and instead recognize
Joel Jaroch, 19, moved to Niceville from Tam- that things are the way they are because he cares. If
pa—roughly 400 miles away—just to learn how to he didn’t care, he wouldn’t pick up the phone when
weld pipe from Smith. they call during odd hours. He wouldn’t be up at the
“He wants you to be the best as you can be. Like, shop during break. He wouldn’t expect the best out
if there’s something small wrong, even if you barely of them day in and day out.
notice it, he’ll tell you about it. Some teachers might “He actually does care,” Quesenberry added.
let those things slide, but not him. He’s very detail- “I’ve seen a lot of the teachers who do only what
oriented. If you have any flaws, he’ll want you to they have to. He goes above and beyond with
perfect them. You can never get it perfect, though. everything,”
That’s the thing to always improve,” Jaroch said. It’s not about the awards or the accolades, even
Scarlett Quesenberry, 18, fell in love with weld- though Smith has plenty. In 2016 he received the
ing while taking a technical theater class that used same honor from AWS that his father did 17 years
GMAW to fabricate sets. She’d never welded pipe earlier—the Howard E. Adkins Instructor Member-
before enrolling in the class, but she developed ship Award.
confidence in her abilities because Smith treated her For him, it’s really about giving people the tools
like anyone else. to transform their lives for the better.
“He doesn’t treat me any differently than anyone “Seeing welding change somebody’s life, that’s
else because I’m a girl. I worked one job where ev- the reward. That’s why I do it. To see somebody
eryone there treated me differently. But he doesn’t. come in who is making only $300 a week and see
He doesn’t say, ‘No, we’ll have someone else do it.’ welding change their life to where they are finan-
He makes me do it so that I learn.” cially stable and can have a career, buy the toys, buy
the house, and provide for their families, that’s the
THE REAL REWARD payoff. That’s the best reason I do what I do.”
THE
It’s late May, and even though the program is

currently on break, a handful of students occupy Editor Amanda Carlson can be reached at
amandac@thefabricator.com.
booths, perfecting their technique. The number of

GTAW
How to weld
aluminum
with GTAW
Tips for sound,
aesthetically pleasing weld
Adding more filler metal is one

technique you can use to achieve
the stacked-dimes look when
welding aluminum with GTAW.

GTAW
By Andrew Pfaller In addition to properly controlling heat, consider

these tips to optimize results when welding alumi-
Manufacturing products with aluminum can help num with GTAW.
extend part life, reduce weight, and deliver greater
integrity in cold temperatures, making the material USE THE RIGHT POLARITY
well-suited for applications such as truck and Many operators, especially those new to aluminum
trailer manufacturing, cryogenic piping, and boat welding, may not realize the material generates an
components. oxide layer. Oxidation on aluminum tends to be a
However, welding aluminum presents some dull silver color and is harder to see than red oxida-
challenges, from controlling heat input to deal- tion, or rust, on steel. In addition, the melting point
ing with the oxide layer. Gas tungsten arc welding of aluminum oxide is about three times the melting
(GTAW) has traditionally been considered the go-to temperature of the base material.
process for welding aluminum because of the high Cleaning the oxide layer with a dedicated stain-
weld integrity and aesthetic appearance the process less steel wire brush or carbide cutter before weld-
provides. ing is important. However, even with proper clean-
Achieving high-quality welds—and getting the ing, the oxide layer begins re-forming immediately,
coveted stacked-dimes appearance—when welding which can obstruct your view of the weld puddle.
aluminum with GTAW takes practice and skill. It’s This makes it critical to use alternating current
also helpful to follow some key best practices. (AC) polarity with the GTAW process on aluminum.
With AC, the direction of current flow continuously
OVERCOMING ALUMINUM CHALLENGES changes throughout the weld. AC polarity provides a
WITH GTAW cleaning action that helps remove the oxide layer on
While GTAW is a slow process and not typically aluminum, allowing you to see the molten weld pool.
used in high-production manufacturing, it is often
a good choice in aluminum welding applications ADJUST THE BALANCE CONTROL
where productivity isn’t as important as quality and Another step that contributes to making a good
appearance. aluminum weld is setting the proper balance control.
During aluminum welding with the gas metal arc When you are welding in AC polarity, the weld has
welding (GMAW) process, filler metal is fed into the an electrode-negative (EN) cycle and an electrode-
puddle as soon as the welder squeezes the gun trig- positive (EP) portion of the cycle. EN is often consid-
ger. These “cold starts” can result in lack of fusion ered the welding side of the AC waveform, while EP
and insufficient penetration. is where the cleaning or oxide removal occurs. On
With GTAW, you control when the filler metal is modern welding equipment, the balance control fea-
added and are able to establish the puddle and en- ture allows you to adjust the ratio between the two in
sure proper penetration before adding filler metal. response to what you’re seeing in the weld puddle.
Keep in mind that having more control over this vari- While older equipment had a truly balanced
able adds another layer of complexity and operator 50-50 ratio of EN and EP, many modern GTAW
skill compared to other processes such as GMAW. power sources have a factory preset balance control
Proper heat input is a critical factor in successfully of 75 percent EN to 25 percent EP. If small black
welding aluminum with GTAW. Because aluminum flecks appear in the puddle during welding—often
is so conductive, the heat of the weld puddle can referred to as “peppering”—your balance control is
be pulled away quickly. This characteristic requires not adjusted properly. Turning the balance control
putting in a lot of heat to establish the weld puddle. down so there is less EN and more EP helps remove
However, this heat must be controlled to prevent a more oxide during welding and should reduce the
runaway puddle or burn-through. peppering.
Heat in welding is a function of amperage and Turning the EN down to provide more clean-
voltage, which means the higher the arc voltage, the ing action may be necessary when you are welding
more power going into the part. Although welding material that’s been in service or exposed to the
with a longer arc increases arc voltage, which in turn elements and, as a result, has a thick oxide layer that
produces more heat, it also heats a much larger area wasn’t completely removed during material prepa-
of the material. This can cause a runaway puddle ration. But be aware that using a lower balance
that grows quickly. To prevent this, use a shorter arc setting (more EP) puts the majority of the heat on
length to help localize the heat to a small area. the tungsten and can cause the tungsten tip to ball

GTAW
back, which affects your ability to control

arc direction and placement of the weld.
Adjusting the balance control does not
replace the need for proper material prep
and cleaning when welding aluminum.
SET THE AC OUTPUT FREQUENCY

Another factor that makes weld placement
easier is the AC output frequency. This also
can be set and adjusted on modern weld-
ing power sources. AC output frequency
shouldn’t be confused with high-frequency
arc starting, which only comes into play for
arc starting.
The output frequency references how
many times per second the power source
switches polarity. Older GTAW power
sources are 60 hertz, which is determined
by the input power, but modern equipment
has a factory preset of 120-Hz output fre-
quency. The higher the AC output frequen-
cy, the more stable the arc becomes. This
Aluminum is conductive, so the heat of the weld puddle can be pulled away quickly. results in a tighter, narrower arc column that
This characteristic requires putting in a lot of heat to establish the weld puddle, but provides more directional control, allowing
controlling that heat is key to preventing a runaway puddle or burn-through.
you to more easily weld in tight spaces and
weld precisely without the arc wandering.
Turning down the AC output frequency
to 80 or 90 Hz provides a wider arc cone,
which can be helpful when welding an out-
side corner joint.
Use an output frequency of 150 to 250
Hz on thin materials that require accurate
weld placement to prevent heating up a
large area or burning through. For welding
thick materials, a low AC frequency of 80 to
120 Hz is typically well-suited for materi-
als 3⁄8 in. and thicker and will help you to
achieve a wider weld bead profile.
USE APPROPRIATE AMPERAGE

In GTAW, amperage is controlled with a
foot pedal or fingertip control, but it’s best
to set the appropriate maximum amperage
on the equipment. The rule of thumb for
aluminum GTAW is to use 1 amp for every
thousandth (0.001) of material thickness. In
other words, welding a base material that is
1
⁄8 in. (0.125) thick would require about 125
amps.
When the base material is more than ¼
Proper heat input is a critical factor in successfully welding
aluminum with GTAW. in. thick, the rule of thumb begins to devi-
ate, and not as much amperage is needed.
For example, you can weld 3⁄8-in. material
with a 280-amp power source.

GTAW
Joint geometry also can affect the necessary MAKE SAFETY A PRIORITY
amperage. When you are welding a T-joint, the heat While GTAW is traditionally a clean welding process
can flow in three directions, compared to welding a with no spatter, it’s still important to wear the proper
butt joint where the heat can flow only in two direc- personal protective equipment, including safety
tions. This means a T-joint requires more heat input. glasses, a welding jacket, gloves, and welding hel-
met. Since aluminum is highly reflective and requires
SET THE AC AMPERAGE INDEPENDENTLY
a great amount of energy to weld, the arc intensity
Some modern welding power sources allow you to of GTAW can cause sunburn to exposed skin.
set the AC amperage independently, which helps Because it’s so critical to clearly see the arc when
achieve greater penetration and productivity. welding aluminum, consider new helmet technology
With this feature, you can increase the amperage that improves visibility and clarity of the weld pool.
during the EN portion of the cycle to drive greater Technology available on some autodarkening hel-
penetration in the weld, since more amperage is mets allows more colors to come through the lens
generally correlated to more penetration. so you can see more contrast among objects in the
This feature generally is used in higher-amperage viewing area. This can help you to achieve better
applications that may need only 200 amps for the results while reducing eye strain and fatigue.
THE
EP cycle to achieve the necessary oxide cleaning,
but you may want 300 amps for the EN cycle to
achieve more penetration. Setting the AC amper- Andrew Pfaller is product manager, CWI, at Miller
Electric Mfg. LLC, 1635 W. Spencer St., P.O. Box
age independently can also prevent the need for
1079, Appleton, WI 54912, 800-426-4553,
increasing tungsten size, since most of the heat is www.millerwelds.com.
put on the tungsten in the EP portion of the cycle. A
power source with the right technology allows you
to tailor each amperage independently to achieve
the desired results.
The balance control and the independent AC
amperage may sound the same, but they control
two different aspects. Adjusting the balance control
affects the level of oxide cleaning, while adjusting
the AC amperage can provide more penetration
while maintaining tungsten geometry.
ADD FILLER METAL FOR THE

STACKED-DIMES LOOK
Adding more filler metal is one technique you can
use to achieve the stacked-dimes look when welding
aluminum with GTAW.
Because filler metal is a solid being consumed
into a molten liquid, it requires energy to change
the material state—like putting ice cubes into a
glass of hot water. The ice cubes melt but also cool
the liquid.
The same idea applies to adding filler metal
during GTAW. Adding more filler rod causes a
cooling effect on the back side of the weld puddle
that helps produce the stacked-dimes appearance
of the finished weld. Adding more filler metal with
each dab produces a more pronounced appearance,
whereas adding less filler metal with each dab pro-
duces a weld with a fairly smooth appearance.
Although it’s not necessary, some operators also
use the foot pedal to vary amperage to help achieve
the stacked-dimes look. Different welders use vari-
ous techniques but can achieve similar results.

SEMIAUTOMATIC WELDING
There is a right way and wrong way to weld. And even when
done correctly, it is important to be aware of the other factors
that can sabotage the job.
By Steven Guisgond
Identifying and Welding typically is the most critical and scruti-
addressing nized process in fabricated items, weldments, and

pieces of equipment. The integrity of any finished
product requiring welding is only as good as the
common welds joining together the different components

and materials. Because of this critical nature, all
quality assurance inspections and requirements
problems in revolve around the welding operation.

As with any fabrication process, there is a right
wire welding
way and wrong way to weld. And even when done
correctly, it’s important to be aware of the other fac-
tors that can sabotage the job.
SOLID-WIRE WELDING VERSUS

Practical tips for achieving FLUX-CORED WELDING
good-quality welds One type of welding that often is performed is
solid-wire welding. The advantages of this type of
consistently welding are that it produces a very clean weld and it
is better suited for thin metal. A solid wire does not

puddle and flow as needed to fill a joint consistently, of the weld joint to create “dams,” which will help
making it unsuitable for thicker metals. It is also keep the weld from flowing out of the joint.
harder to apply a weld joint accurately as it tends to
stick to one side of the joint more than the other. If WIRE WELDING SIMILAR AND DISSIMILAR
solid wire must be used on thicker material, you may MATERIALS
need to use multiple weld passes and then gouge or Regardless of the material grades being welded or
grind out previous weld passes until the weld joint is whether you are joining similar or dissimilar metals,
fully fused. if you follow proper procedures, you shouldn’t have
Another type of welding is flux-cored welding, a problem making a quality weld. The best way to
in which a hollow wire is filled with flux. The advan- achieve good welds is to develop a thorough weld-
tages of this process is that it is better suited for ing plan for the specific project. Start at the begin-
thick metal, it puddles and flows into weld joints ning and follow the necessary steps one by one until
consistently and accurately, is more forgiving, fuses complete.
equally, and provides good joint penetration. First, study the plans and drawings to identify all
The disadvantages are that the flux-cored wire the types of welds, material grades being joined,
puddles and runs out too flat and quickly when this and the joint preparation required. Second, produce
method is used for thinner metals. The flux burns, sample weld coupons that mimic the welds you will
leaving a charred discoloration on the weld that re- need. You can then send these coupons to a lab for
quires extensive brushing and cleaning to remove. If bend/break testing either through a third-party certi-
you have to use flux-cored wire on thin material, be fied welding inspector (CWI) or an in-house CWI.
sure to use welding tabs at the beginning and end Last, create the procedure qualification report (PQR)
If solid wire must be used on thick material, you may need

to use multiple weld passes and then gouge or grind out
previous weld passes until the weld joint is fully fused.

The best way to achieve good welds is to
develop a thorough welding plan for the
specific project. Start at the beginning and
follow the necessary steps one by one until
complete.
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WHAT MAKES A BAD WELD?

It only takes one wrong move to put the quality of
the weld in jeopardy. Some examples are using the
36" & 1 meter wrong filler metal for the materials being joined;
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spatter. For example, everything on the weld may look Also, calibrating welding machines properly is an
good visually even if you use the wrong filler metal or important factor in controlling quality. Over time weld-
electrode. However, problems can arise later in the ing machines tend to lose their calibration and perfor-
product’s life when it is in use. During the stress of mance. When this occurs, consult a calibration expert
operation, vibration, and hot and cold expansion and who can test the machines periodically to make sure
contraction of the metal and welds, the wrong filler the performance output matches the settings entered
metal may have less or more expansion than the met- into the machine. A properly calibrated welding ma-
als it joined together. This difference could cause the chine is a necessity to get the proper performance.
welds to break, leading to product failure and physical Finally, ensure the wire that you are using is in
or financial damage to the end user. good condition. There are quality procedures that you
need to follow when purchasing and storing new and
QUALITY CONTROL used welding wire spools. Moisture and cool weather
Properly certifying welders is a requirement for con- can damage the weld wire, whereas rust and other
trolling weld quality. A welder qualification is similar to contaminants can damage the quality and integrity of
the weld procedure qualification (WPQ) in which test the filler metal. Because of this, store welding wire in
coupons are welded together. The coupon undergoes a temperature-controlled storage cabinet when it’s not
a bend/break test, and upon satisfactory results, the being used.
THE
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passed. Certified welders are issued a stamp num- Steven Guisgond is general manager at Ci Metal
ber, which is used during production to identify who Fabrication, 6205 St. Louis St., Meridian, MS 39307,
performed the welding. This initiates accountability 601-483-6281, www.cimetalfab.com.
and traceability, which increase quality assurance of
the welder.
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Q&A
Family, friendship,
and metal fabricating
7 questions with S&K Sheet Metal LLC
By Amanda Carlson Recently Shipp, Kramer, and Shipp’s wife Erika

sat down with The WELDER® to talk about the first
Many welders and metal fabricators dream about few months of business, the highs, the lows, and
opening their own business, being their own boss, everything in between.
and building something that belongs to them.
But when the rubber hits the road, not many are
willing or able to do what needs to be done to be TW: What led you to want to start your own
successful. company?
After all, metal fabricating equipment isn’t cheap CS: I was getting pretty frustrated with the travel-
and neither is a space to house it. And even if you ing. Erika and I have four kids and I rarely saw them.
manage to acquire both, there’s no guarantee you’ll I drove two and a half hours each way to and from
have enough business come through the doors to work for three years straight. I’d wake up at 3:45
pay for it or to even pay yourself and support your a.m. and get home around 5:30 or 6 p.m. I’d come
family, much less make a profit. home at night and pretty much be ready to crash.
But the rewards were worth the risks for Cody TK: Most people in his situation would just stay
Shipp and Tony Kramer. The two longtime friends the entire week at the job site and then come home
and co-workers can now call themselves business on the weekends, but he didn’t want to be away
co-owners. The friends originally met while Kramer, from his family.
now 29, was in high school and Shipp, now 33, was ES: I work every Saturday, so we just didn’t have
his wrestling coach. They worked at the same com- a ton of time all together as a family. I just felt bad
pany, Shipp out in the field installing metal products for him because he spent so much time on the road.
using mostly gas metal arc welding (GMAW) and It wasn’t hard, but mostly I felt bad for him because I
Kramer welding mostly in the shop with a specialty knew how unhappy he was.
in stainless steel gas tungsten arc welding (GTAW).
Today Shipp and Kramer are the S and K in S&K
Sheet Metal LLC, a custom job shop located in Mon- Right: The rewards for opening a new business were worth the
roeville, Ind. They officially opened their doors last risks for longtime friends Cody Shipp (far left) and Tony Kramer
(far right). They are they S and K in S&K Sheet Metal LLC, a
fall and have been learning on the job ever since.
custom job shop located in Monroeville, Ind. With Shipp’s wife
Their goal is to keep it a small family affair that Erika, they officially opened their doors last fall and have been
aligns with their values. learning on the job ever since.

Q&A

Q&A
WE WERE GENUINELY
SURPRISED WITH HOW MUCH
CS: The last job that I had was work while he does most of the
a shutdown job, and as soon as WORK WE GOT IN THE FIRST stick welding. We share the MIG
the shutdown was over, I knew I’d welding duties.
COUPLE OF MONTHS. EVEN
get laid off. Well, as soon as they CS: I am working on get-
said “Next week we’re done,” it THOUGH WE WEREN’T ting better at TIG. I’ve always
really started to hit me that I did welded out in the field but I’ve
MAKING A BUNCH OF MONEY,
not want to go back to where I never really been in the shop.
was or to a similar employer. So, I JUST GETTING SOME Tony, on the other hand, spent
got on the computer and tried to the last few years of his career
PROJECTS THROUGH THE
figure out the difference between TIG welding constantly, so he’s
an LLC and an Inc., and I started DOORS ALLOWED US TO really good. He does most of
getting info from CPAs and picking the stainless work that we have
INVEST WHAT WE MADE BACK
people’s brains until I decided that in the shop right now. I’ll cut it,
I was going to form this company INTO THE COMPANY. prepare it, and get it all ready,
right now. and then when it comes time to
TK: Cody has way more to lose than I do. He has actually put some heat on it, it’s all him.
four kids and a wife. For me to pick up from where We complement each other well. Between the
I was and just leave, the worst thing that could hap- two of us we are pretty well rounded. What one
pen was it wouldn’t work out and I’d go back. To lacks that other one makes up for. It’s one of the
hear that he was actually serious about it made it reasons why we teamed up to begin with. And
real for me. now Erika is starting to get into doing the office
work. She’s had to continue working part time as a
hairdresser because we needed some sort of income
TW: What have life and business been like since
coming in for our family.
going out on your own?
TK: When we put in our notice at work, our boss
said, “You can bid 100 jobs and you might only get TW: Where do you foresee the business going?
one.” So far people have been happy with our work, TK: Right now our focus is on welding and repair,
and more work has come our way as a result. So, we but if I had to pick it would be specialty stainless
joked with each other and said, well, maybe what he steel work. I’d like to see us get into food-grade
meant to say was if you bid one job you get 100. All stainless. It’s something that I enjoy doing, and it’s
kidding aside, we’ve been very fortunate so far. a niche that would set us apart from other welding
CS: Having more independence has been huge. and fabricating companies.
The fact that I don’t have to spend half the day in CS: I agree. We are definitely going after the
the car is huge. Also, we make our own schedules. stainless fabrication type of work. The food-grade
If I work late one night, I can sleep in a bit the next stainless work really lets us show what we’re capable
morning. If my kids have an event at school in the of, plus when you get into doing stainless, you’ve
morning, I can attend. I’ve already taken them to got stuff that ends up looking really cool.
school more now than I ever have. TW: How would you sum up the last six months
ES: It’s nice that he’s home, especially if some- of your business?
thing were to happen with the kids and we really CS: I’d say it’s gone very smoothly. We didn’t
needed him. Now he’s just down the road or some- really anticipate all the support that we’ve received.
where around town instead of being two and a half We didn’t start a business thinking that people
hours away. would help us out. Even though we haven’t gone
out of our way to ask for help, people have offered
it. We were genuinely surprised with how much work
TW: What is the breakdown of responsibilities we got in the first couple of months. Even though
among the three of you? we weren’t making a bunch of money, just getting
TK: Cody does a lot more with customer relations some projects through the doors allowed us to
and he goes and meets the people. I stay back at invest what we made back into the company.
the shop and do whatever work we have to do. As far as our goals for this year, we planned to do
We fabricate and weld using MIG, stick, and TIG. a lot better than we did in the last couple of months,
He’s the better stick welder and I’m the better TIG but we’re really excited about what will happen once
welder. I do most of the TIG welding and stainless the weather warms up. There were some really cold

Q&A JOIN US FOR THIS FREE WEBINAR
Brought to you by thefabricator.com
months. We had no heat; we didn’t have anyone
stopping by here; we just felt like we needed the AUTOMATED DEBURRING
FOR OPTIMIZED FABRICATION
weather to break. And sure enough, as soon as
it warmed up a little bit, we had people coming
through the door, poking their heads in, and ask-
ing for things. & ASSEMBLY
We’re really looking forward to getting to
know the community so that we can build some
relationships.
TW: How have you been able to acquire

equipment without going into debt?
TK: Just about every dollar we’ve made has
gone right back into the company, which is why
he and I are still poor.
CS: It seems like every time we do a job we’re
buying another machine. We bought this plasma
table; it’s a 5- by 10-ft. CNC plasma table. We
also recently purchased an ironworker. We just
bought a 10 ft., ¼-in. plate shear at an auction.
Presented by:
It was originally owned by the U.S. Navy and was
brand new in 1967. We also have a 12-ft., 100-
ton press brake from the 1960s. It’s got some
leaks but it bends metal. We’re also eyeballing
a plate roller. Something that will roll a 6-ft.-long
piece of metal that is ¼ in. thick.
Just like Tony said, every penny we make Date: Tuesday, August 21, 2018
goes right back into the company. As long as we Time: 1:00 p.m. (CST)
have enough to pay our personal bills, we’re just
barely surviving that way so that we can afford
to get the equipment we need in here without This webcast will include the following topics:
going into debt. • Various types of deburring processes
TW: What advice would you give to those • Types of deburring machine configurations
looking to branch out on their own? • 1-sided vs. 2-sided
CS: You’ve got to be able to be OK with not liv-
ing the same life you were before. That’s advice • ROI for automated deburring
I would give. You’ve got to be willing to make • Why automate deburring
some sacrifices. You have to be pretty financially
smart as far as how you spend your money. • Integration of automated deburring with robots
From our perspective, it’s worked to reinvest the
We will also answer any questions you might have about auto-
money that we’ve made back into the company
and take a smaller cut personally. And we’re
mated deburring and our machine itself.
both willing to do that for a year or two or how-
ever long it takes to get the equipment in here Deburring Edge rounding
that we need to really be the company we want
to be. We’re only a few months into this, but so
far it’s worked for us.
THE
Editor Amanda Carlson can be reached at

amandac@thefabricator.com.
S&K Sheet Metal LLC, 260-760-3249,

www.facebook.com/SandKMetals/
Register today for this free webinar!

July/August 2018 31 Visit www.thefabricator.com/webcast

FINISHING
Cutting,
grinding,
and
finishing
7 tips for success
By David Jescovitch and Stephen Schafer
Getting the best results in metal cutting, grinding,

and finishing applications is a balance of numer-
ous factors, including choosing the right abrasive
product for the job and following best practices
for product use and storage. It’s also important to
look beyond the specific abrasive application and
consider the big picture. What is happening in the
entire fabrication or manufacturing process from a
cost and productivity perspective?
Before selecting a product, contact your abra-
sives manufacturer or local distributor to discuss
the results you desire. It’s much easier to achieve
success when the process and the abrasive product
are considered from the beginning. From there,
consider these seven common tips to help optimize
productivity, performance, and safety in cutting,
grinding, and finishing applications.
TIP NO. 1: IDENTIFY YOUR DESIRED

END RESULT
Knowing what you’re trying to accomplish is the first
step in choosing the right abrasive product. Com-
pleting rough grinding after a deburring operation
requires a different process and products than does
blending or finishing, for example.

FINISHING
When using cutting wheels, hold the tool at a 90-degree angle, perpendicular to the workpiece.
This enhances safety and helps improve wheel life and cut rate.

FINISHING
A common pitfall in surface finishing is using the TIP NO. 2: KNOW THE MATERIAL
same wheel no matter the job. Always match the The type of material you are grinding or cutting is
abrasive product to the task at hand. Identify your another key consideration for choosing the right
desired results and then plan the process that will product and getting the best results. Different mate-
produce those results. Choosing the right product rials require different conditions and best practices.
for the job requires an understanding of the entire Stainless steel typically involves more stringent re-
process. Will the part be painted, anodized, or have quirements to prevent expensive damage. Products
chemicals applied? All these factors play a role. designed specifically for stainless steel help improve
As a rule, grinding wheels are used for rougher material finish and overall work flow by reducing
finishes that won’t be painted, while flap discs grind heat buildup and workpiece staining.
and finish at once and produce relatively fine finish- When you are working with aluminum, it’s impor-
es. Resin-fiber discs can be used for a short lifespan tant to reduce the amount of material loading on
to grind quickly with a relatively fine finish. the wheel or disc face. If your disc is not designed
The desired finish for the material also impacts specifically for aluminum, you’ll wind up constantly
the needed grain type and grit size of the abrasive swapping out a disc or wheel that has been loaded,
product. Generally, 24- through 50-grit discs leave a leading to more downtime and higher overall cost.
relatively rough finish and are used to remove a lot Know the material to determine the appropriate
of material quickly; 60- to 100-grit discs fall in the bond for grinding or cutting wheels. It’s a good rule
middle of the spectrum and are typically used when to choose a product with a softer bond when condi-
the surface will be grinded and painted; and grits of tioning harder materials and choose a product with
100 or more should be used to achieve fine finishes. a harder bond when conditioning softer materials.
When considering costs, keep in mind the overall This helps maximize product life and cutting ability.
process rather than just the cost for each abrasive The bottom line: The more you know about the
disc or wheel being used. The required labor and base material, the better your results.
time for any rework can have a big impact on overall
costs. For example, a cutting wheel that minimizes TIP NO. 3: MATCH THE DISC TO THE TOOL
surface burn of the material makes part fit-up much Correctly matching the tool and abrasive can deliver
easier and faster. significant cost savings and productivity gains as
A common pitfall in
surface finishing is using
the same wheel no matter
the job. Always match
the abrasive product to
the task at hand. Different
materials require different
conditions and best
practices.

FINISHING
the efficiency of the abrasive is directly affected and what materials it should be used on. Storing the
by the tool it’s being used on. If the wrong tool product in the original packaging helps reduce the
is used for the job, problems will arise even with risk of cross contamination, which is a critical issue
the right accessory. In grinding especially, it’s key in some applications. Any product used on carbon
to match the appropriate abrasive product to the steel, for instance, should not be used on stainless
highest-performing tool (based on amperage or steel or aluminum.
RPM) allowed by the job. For example, using a low- The risk for contamination is high when a wheel
amperage tool with a 14-gauge extension cord can’t is left on a grinder. When the grinder is taken back
turn the grinder fast enough to provide optimal to the toolroom, it becomes difficult to remember
performance. which material the product was used on previously.
In addition to proper storage, always inspect the
TIP NO. 4: STAY IN MOTION abrasive product and the tool for any cracks or dam-
With any abrasive product it’s important to keep age before using it.
the wheel or disc in constant, smooth motion and
avoid bearing down with heavy pressure or dwell- TIP NO. 7: ALWAYS BE SAFE
ing in one spot. Constant motion reduces the risk of Beyond choosing the right product, following
gouging or material damage and helps prevent heat proper safety procedures is also critical to success.
buildup that can cause discoloration. The most important safety practice is to always use
Pull the initial stroke toward you rather than the tool guard.
pushing the tool away from your body. This greatly Safe operation
reduces the risk of gouging, especially when you are also involves watch- AS A RULE, GRINDING WHEELS
using a new wheel. ing the speed. The ARE USED FOR ROUGHER FINISHES
RPM rating of the
TIP NO. 5: WATCH THE ANGLE accessory should THAT WON’T BE PAINTED, WHILE
Position the tool at a slight angle to the workpiece meet or exceed the
FLAP DISCS GRIND AND FINISH AT
when grinding. Increasing the angle of the grinding RPM rating of the
wheel provides more aggressive grinding but reduc- tool. For example, a ONCE AND PRODUCE RELATIVELY
es wheel life. Reducing the grinding angle lessens 7-in. grinding wheel
the pressure being applied to enhance product life, that is worn down FINE FINISHES. RESIN-FIBER DISCS
but it also minimizes cut rate. to a smaller size CAN BE USED FOR A SHORT
Grinding or finishing at an angle that is too steep should not be used
may cause you to work much harder than necessary on a 5-in. grinder, LIFESPAN TO GRIND QUICKLY WITH
since you’re not getting the full benefit the product because the wheel
A RELATIVELY FINE FINISH.
is designed to provide. was not designed
When using cutting wheels, hold the tool at a to be used at the
90-degree angle, perpendicular to the workpiece. much higher speed of the smaller tool. Also, if you
This position enhances safety and helps improve can’t read the RPM rating on either the tool or the
wheel life and cut rate. abrasive product, don’t use them.
It’s critical to use grinding and cutting wheels as It’s also unsafe to use an abrasive product on a
designed to enhance safety and get the best perfor- task for which it wasn’t designed, such as using the
mance and efficiency. sides of a cutoff wheel to perform grinding or de-
burring. Grinding with the side of a cutoff wheel—
TIP NO. 6: STORE EQUIPMENT PROPERLY even for a few seconds—can damage the wheel and
Storage recommendations depend on the type of reduce the fiberglass reinforcement, causing the
product you use. Resin-bonded abrasives should be wheel to break apart.
stored at ambient temperatures, as exposing them Any product modifications can compromise
to big temperature swings negatively affects the safety and efficiency. Be sure you’re following the
bonding agent. Compare this to coated abrasives recommendations for proper use. You can also try
(flap discs), which are less susceptible to changes in using a different wheel or disc to improve perfor-
temperature. mance for the application.
THE
With any abrasive product, store it in the original

David Jescovitch is abrasive specialist manager
packaging when possible. If you remove the disc or
and Stephen Schafer is territory manager at Weiler
wheel from the package and then store it in a tool- Abrasives Group, 1 Weiler Drive, Cresco, PA 18326,
box, you may lose track of what type of product it is 800-835-9999, www.weilercorp.com.

WELDING HACKS
Simple ideas make life as a welder a lot easier
ANGLE GRINDER HANGER FOR SHOP ORGANIZATION

I don’t like taking the time to keep changing wheels on my angle grinder, so I fabricated one
and mounted it to my brake.
I used 3- by 3- by ¼-in. angle iron for the uprights and the crossbar. I bolted them to the
frame of my brake because it’s in the center of my shop. This makes it easy for me to grab one
of the grinders when I need it and it provides a convenient place to hang them out of the way
when I’m finished.
Joe Campoli
Mishawaka, Ind.

LONG-BAND CUTTING
MADE EASY
I have an easy way to cut a long band from a
sheet or a coil using only a simple jig and a
plasma cutter. You can make the jig adjust-
able, depending on your needs. In my case,
the jig is not adjustable.
The design is simple. Weld two pieces
of a flat at a 90-degree angle. The first flat
has the hole for the plasma torch (the length
from the edge of the flat to the center of the
hole will be the width of our band). To the
second flat, weld another flat piece along
the edge.
Our jig uses a side of the coil as a guide
line. Just take a plasma torch, put it into the
hole, pull the jig along the side, and then
cut. It is extremely easy, and you do not
have to keep any long rulers in your shop.
Oleksii Kryvytskyi
Cartwright, Manitoba, Canada
Share with us your advice, idea, welding hack, tip, or trick. If we publish your trick, you’ll win a $100 gift card.
To submit a tip, trick, or hack, please send clear photographs or detailed drawings and a complete explanation of your idea. With each
entry include your name, address, and telephone number. Send your ideas to Amanda Carlson, FMA Communications Inc., 2135 Point
Blvd., Elgin, IL 60123, amandac@thefabricator.com.

PLAYING WITH FIRE
Admitting you don’t know

everything is the key to learning
By Josh Welton
“There is nothing noble in being superior to your fellow man; true nobility is being superior
to your former self.”—Ernest Hemingway
The late Tom Soley was a welder who could do it all. TIG, stick, gas,
or MIG, it didn’t matter the material or the position, he handled it. He
was an artist, an inventor, a fabricator, and a metallurgist. He was an
instructor at the UAW/Chrysler Train-
ing Center during my time there,
and he was very much a mentor to
me in those early years. But as much
as he was a teacher, he was also a
student of the craft. The most impor-
tant lesson he taught me was that
no matter how much experience you
have, there is always room to grow.
Tradespeople with a wide range
of backgrounds and skill levels
passed through Tom’s classes, and
despite his more than four decades
deep in the wild world of welding, if
his students had a new idea or tech-
nique to share, he was all eyes and
ears. If it was an ill-conceived idea
he’d explain why and show them a
better way, or maybe a couple of
better ways. But if the trick had legs,
he tried it out, usually mastered it, and added it to his proverbial “bag
of tools.” That doesn’t happen if you don’t leave open the possibility of
learning, which means admitting you don’t know it all.

PLAYING WITH FIRE
HUMANS ARE ALL WIRED

DIFFERENTLY; WE ALL LOOK AT THE
WORLD UNIQUELY AND RESPOND
TO DIFFICULTIES IN OUR OWN WAY.
SOME PEOPLE STAY COOL AND
COLLECTED AND METHODICALLY
Humility and welding do BREAK DOWN BARRIERS. which was basically the
not typically walk hand in back part of the build-
hand, and only a few people PERSONALLY, I TEND TO BE PRETTY ing where all the metal
I’ve known mastered that STUBBORN AND HOT-TEMPERED chips from the machining
balancing act the way Tom process were spit out and
did. Like athletes, or fighter WHEN I FACE AN OBSTACLE. then taken away.
pilots, or rock stars, welders There were manganese
often have a certain swagger that only comes with chutes through which many tons of metal passed
the conviction in one’s own ability. To be a good every day. They’d wear out and we’d patch them
welder you need to have a talent and vision that not up to last until we could replace them. The process
all are born with, terrific hand-eye coordination, and involved welding a lot of good sheet metal to erod-
experience that is gained only through hard work ing, paper-thin metal with 6010 electrodes. It wasn’t
and time. There’s a lot to be proud of. a crazy-hard weld, but 6010 is a sticky rod, it was out
John Kacir, the head of Macomb Community of position, and I was a kid without a lot of experi-
College welding department, was one of the first ence. I’d stick the rod to the plate, or blow through
people I ever saw don the mask. He was robotic as the metal, or otherwise make a mess of it, curse, and
a welder. He once told me that almost every good try again.
welder he met had at least a certain amount of “ar- Chris was about 10 ft. away by the humming
rogance.” But to be great, you have to understand Trailblazer talking to another millwright as I was
your limitations. And everyone has limitations. The repeating this mad cycle over and over again.
scope of what welding knowledge entails is too vast The other millwright said to Chris, “Shouldn’t you
for any one person to know everything. It’s easy to go help him?”
say you’re willing to learn new things, but for some “Not yet…” he said.
reason very few live and work with a mind open to “Why not?”
new ideas, methodology, or even techniques. I be- “He’s not ready yet.”
lieve we almost need a morning mantra to meditate “How will you know when he’s ready?”
on, like “I will learn today.” Otherwise, we all easily About that time, I stuck the rod again, threw my
slip into grooves of complacency. helmet in anger, and tossed a few choice words at
While some people are good at figuring things the metal as I stomped away and past them both.
out from scratch, I’ve always learned best from “He’s ready now,” Chris said.
hands-on instruction. Even just understanding how So Chris grabbed his helmet, picked up the sting-
you come to understand something is so important. er and a rod, and started welding on the chute like
Humans are all wired differently; we all look at the it was the easiest thing in the world. He never said
world uniquely and respond to difficulties in our anything to me because he knew I’d come around.
own way. Some people stay cool and collected and And I did. I cooled down and returned to the scene
methodically break down barriers. Personally, I tend of the crime and just watched him. He knew how my
to be pretty stubborn and hot-tempered when I face brain worked and that I wasn’t going to listen to rea-
an obstacle. son until I exhausted my limited skill and patience.
As a young millwright apprentice at Chrysler, I But when that time came, I was a quick study and he
worked with a journeyman named Chris Bianco. He was a good teacher.
understood me and where I was at in my education “I don’t know.”
and how I learned. I remember on one occasion we It’s easy to say yet hard to admit. But getting to
were working in the engine machining area’s gallery, that point is the only way to grow.
THE

ALUMINUM WORKSHOP
Frank G. Armao is president of Aluminum

Consulting Inc., 440-479-0239, frankarmao2@
gmail.com. He is a member of the AWS D1
Committee, chairman of the AWS D1 Aluminum
Subcommittee, and member of the Aluminum
Association Committee on Welding and Joining.
Why isn’t 7075 weldable?

I fabricate high-end, custom, aluminum-framed bicycles. I was able to buy round
tube made from alloy 7075-T6 in the correct sizes to make bicycle frames. I checked
the mechanical properties and found out that the strength of this alloy is very high.
However, I have been unable to find the correct filler metal for this alloy. Can you
help me?
I’m afraid that you have made a very bicycle frame from 7075. While it may look
common, and in your case a very costly, fine, it will most certainly fail the first, the
mistake. The problem is that while most fifth, or the 10th time you ride it. I’m sure you
aluminum alloys are very weldable using a don’t want that.
fusion welding process (any process that In fact, while the alloys in the 1XXX, 3XXX,
melts the aluminum, such as GTAW, GMAW, 4XXX, 5XXX, and 6XXX series are virtually all
and laser welding), some are not. The alloy weldable, most alloys in the 2XXX and 7XXX
7075 falls into the unweldable category. Ad- families are not. There are exceptions to this.
ditionally, alloy 2024 falls into the unweldable In the 2XXX family, 2014, 2219, and 2519 are
category as well. Both are very high-strength readily arc weldable. The rest are not. In the
aerospace alloys used 7XXX family, 7003, 7005, and 7039 are arc
to fabricate airframe weldable. The rest are not. Please note that
MY FURTHER structures that were when I say weldable I am talking about fusion
developed without welding processes. All are weldable using
RECOMMENDATION IS any consideration more exotic processes that don’t melt the
of their weldabil- base material, like friction stir welding. But
THAT THE NEXT TIME ity. There is a good those are beyond the scope of this column.
SOMEONE ASKS YOU reason that these So, back to your question. What should
structures are riveted you do? My recommendation is to scrap the
TO WELD 7075 OR 2024, and not welded. 7075 you bought or divert it to applications
Why aren’t these that don’t require welding. I know that this
RUN OUT OF THE ROOM alloys weldable? It all hurts. However, if it makes you feel better, I
SCREAMING AND DON’T comes down to their once had to make the same recommenda-
chemistry. It’s not that tion to a fabricator that had bought 7075 and
LOOK BACK. you can’t get them to spent $500,000 in making parts from it before
stick together—you he asked the same question that you did.
can. However, the My further recommendation is that the
heat-affected zones of the weld are extremely next time someone asks you to weld 7075
prone to cracking and stress-corrosion crack- or 2024, run out of the room screaming and
ing while in service. So, you could weld a don’t look back.
THE

THE
The Power of Print

Did you know that 91% of adults (18+) have read some type of magazine within the last
6 months? And it’s not just the “older generation” …this number climbs to 94% of those
under the age of 35. And 94% of those under the age of 25. And this audience continues
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in the five-year span from 2012 to 2016. *
Print is an integral part of a successful marketing plan that also includes online marketing
as well as in-person events (trade shows, etc.). For over 20 years, The WELDER® has served
the welding community in North America and we intend to continue providing hands-on
information, real-world applications, and down-to-the earth advice for welders.
The WELDER reaches over 30,000 qualified and BPA-audited subscribers every issue, and
they like what they see. According to a 2018 readership survey, 99% of resondents trust
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CONSUMABLES CORNER
Nino Mascalco is application Rob Koltz is application Steve Sigler is application

engineering manager, ESAB engineer, ESAB Welding & engineer, ESAB Welding &
Welding & Cutting Products, Cutting Products, Cutting Products,
636-485-2253, www.esabna.com 636-485-2253, www.esabna.com 636-485-2253, www.esabna.com
Aluminum welding for the

non-aluminum welder
We’re a small fabrication shop that is expanding and experiencing some growing
pains. We normally work with carbon and some stainless steel for the majority of our
work, but we’re attempting to branch out and become more diversified to better
serve our customers. We recently took on some 6061-T6 aluminum jobs and we’re
struggling with weld quality using 4043 MIG wire and 100 percent argon. Some of
the issues are lack of fusion (LOF) at the root of the weld joint and weld bead profile.
What should we do?
It’s great to hear that your business is a helium/argon blend between 25 and 75
growing! To provide some insight, we’ll make percent helium with the balance of argon.
some assumptions, but the end results will be Helium produces a much wider arc cone
minimally affected. throughout the length of the welding arc
The type of aluminum you are using is and more heat. This is beneficial for achiev-
referred to as structural-grade aluminum. As ing adequate penetration at the root, better
with most metals, there are several differ- bead appearance, and higher travel speeds.
ent types and grades that take advantage It is best-suited for thick sections of base
of alloying elements and specific processing material. Keep in mind that more helium
techniques to optimize their performance means you’ll need to set the flow rate higher
for their intended applications. The T6 is a to provide adequate shielding coverage. This
solution heat-treated, artificially aged grade is necessary because helium is lighter than
of aluminum that is readily weldable and pro- atmospheric air and will float away before it is
vides good strength and corrosion resistance. effective.
The most common filler metal is the 4043 Many variables can affect the weld perfor-
you are currently using, but you could also mance and results in aluminum, but the most
choose from several others depending on important variables are the ones that occur
the desired results. If your weld bead profile before welding. Properly preparing the joint
problems are cosmetic, such as weld-toe is essential to producing a quality welded
angle transitions or general bead appear- joint. Be sure to remove any dross or con-
ance, you could substitute 4047, which has a tamination from thermally cut edges from the
greater amount of silicon that will produce a base-material joints. Clean the joint before
more fluid weld puddle. fit-up and welding is the most important.
In many cases, straight argon as a shield- Aluminum has a protective oxide layer
ing gas is commonly used, and many shops that you need to remove before you weld.
will have this on hand if they perform any Although this oxide forms readily in the
GTAW. The problem with pure argon is it pro- atmosphere, removing it in turn eliminates
duces a narrow arc cone, limiting the penetra- the additional contamination and moisture
tion profile width, which could explain your that goes with it. Use a solvent to remove oil,
problems with fusion. grease, or moisture before you file, grind, or
A better option for welding aluminum is wire brush the surface and edges of the joint

CONSUMABLES CORNER
you are about to weld. Be sure to use a stainless steel

wire brush dedicated to cleaning aluminum only. This
will keep it clean and prevent cross-contamination. Do
the same with grinding or sanding wheels.
m For aluminum GMAW, set parameters to weld hot
and fast in direct-current electrode positive (DCEP).
Sometimes LOF occurs at the root because the travel
speed is too slow and arc energy is too low. Since you
have little control over the rate of filler metal being
added to the joint (unlike with GTAW where you have
complete control), what happens is the welding arc will
be focused on top of the molten weld puddle instead
of in front of it. This produces an insulating effect at the
root of the joint and leads to LOF. Using higher weld
parameters in a spray-transfer mode with a pushing or
forehand technique while keeping the arc focused at
the leading edge of the weld puddle will produce the
best penetration results. A simple T-joint break test will
verify that your settings and technique are correct and
identify if you’ve achieved sufficient penetration.
Changing your shielding gas and following the
guidelines outlined here should have you producing
quality welds in no time.
CSU-201407-PWT 1_2pg horiz_Layout 1 6/19/14 4:08 PM Page 1
THE
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PRODUCT NEWS
FILTERS CAPTURE TOXIC DUST

AND SAVE SPACE
Camfil APC dust collectors now are available with
Integrated Safety Monitoring Filters (iSMFs) to
isolate toxic particulates, ensuring that no measur- WELDING PROCESS COMBINES
able weight of emissions is being discharged. They LASER WELDING AND GMAW
are available in HEPA-grade or ASHRAE-grade for Fronius has introduced LaserHybrid welding, which
operations that produce toxic dusts such as manga- combines laser welding and GMAW in a single pro-
nese, hexavalent chrome, nickel, and zinc oxide. cess. According to the company, this highly stable
The filter units are installed at the factory on welding process requires less preliminary work and
top of the company’s standard Farr Gold Series® rework while offering high speed and high quality.
dust collector, which minimizes the total footprint. During the process, a laser beam initially heats
No additional ductwork, transitions, or supports the surface of the component, resulting in deep,
are required. Hazardous particulates are contained narrow penetration. The arc then forms a wide weld
because the filter unit allows filters to be located be- pool to bridge the gap while achieving deep pen-
fore the fan, keeping them under negative pressure. etration. The compact welding head has an integrat-
These afterfilters also prevent collected dust ed GMAW torch and built-in laser optics. Different
from re-entering the workspace if there is a leak in welding heads are available for applications in the
the primary filters and stop flames that occur from automotive, shipbuilding, and pipeline industries.
combustible dust incidents, protecting downstream A robot holder forms the link between the weld-
equipment. The filter units are monitored for changing head and an industrial robot. This gives the head
es in differential pressure and can be programmed the flexibility to access difficult-to-reach areas of the
to signal an alarm or shut down the dust collector, if component. The welding wire can be placed in any
necessary. position with respect to the laser beam.
Camfil APC, www.camfilapc.com Fronius USA LLC, www.fronius.com
WELDING JACKET INCLUDES FR COTTON

STRETCH KNIT BACK PANEL
Black Stallion® has introduced the JF1625-NG stretch-back fire-resistant
cotton welding jacket. The looped knit yarns of the back panel are extremely
flexible to offer horizontal stretch for shoulder and arm movement. The
looped knit yarns also allow increased airflow through the fabric for im-
proved worker comfort.
The back panel offers fire resistance compliant with ASTM F1506, and
the front, shoulders, arms, and neck are constructed of 9-oz. flame-resistant
cotton. The stand-up welder’s collar with snap closure helps keep sparks off
the neck.
Black Stallion, www.blackstallion.com

PRODUCT NEWS
WELDING HELMET FEATURES INTEGRATED FLIP-UP GRIND SHIELD

Lincoln Electric® has introduced the VIKING™ 3250D FGS™ welding helmet. It features
a flip-up grind shield to increase the operator’s field of view in both open and closed
positions through the integration of a clear face shield and side windows.
The helmet’s optic design, 4C® Lens Technology, eliminates blur, distortion, and eye
strain by reducing color saturation in the LCD while also providing a consistent shade
at any angle. This technology scores a 1/1/1/1 rating on the EN 379 autodarkening
lens quality standard. The autodarkening viewing area is 12.5 sq. in.
Lincoln Electric, www.lincolnelectric.com
Modular Fixturing Solutions | Safety Focused | Lifetime Warranty
SAFETY
WITHIN
REACH.
CERAMIC RESIN FIBER
DISCS FORMULATED
FOR USE ON HIGH-
PERFORMANCE ALLOYS
Mercer Industries has introduced its When employees are forced to reach or bend awkwardly, productivity slows
Ceraflame 2™ resin fiber discs. They and the chance of injury increases. Bluco modular rollover fixtures enable
operators to work in a proper ergonomic position while reducing the stress
feature a high concentration of ce-
of repositioning weldments. Our Application Engineers can tailor a modular
ramic grain lasting 40 percent longer rollover solution to meet your unique application.
than the original grain, according to
the company.
The discs are formulated to be
Rollover fixtures can be
used on high-performance alloys, configured an unlimited
high-carbon steel, stainless steel, number of ways with
Bluco’s extensive line of
nonferrous metals, and heat-sensitive modular tooling.
metals. They have a heavy-duty, vul-
canized fiber backing and a top size
coating for cool, fast cutting. Avail-
able in grits from 24 to 80, they can
be used to strip, grind, deburr, and
polish. The discs are contaminant-
free to prevent stainless steel from
rusting and will not stain or burn
material, the manufacturer reports.
The discs are available in 41⁄2- by
7
⁄8-in. hole with a maximum RPM of
13,300.
Visit bluco.com or VISIT US AT
Mercer Industries, BOOTH C12028
call 800-535-0135
www.mercerindustries.com

PRODUCT NEWS
MULTIAXIS WELDING POSITIONERS

AVAILABLE WITH UP TO 5 AXES
GRINDING WHEELS GRIND, CUT, LazerArc offers multiaxis welding positioners. Avail-
AND UNDERCUT able with 3, 4, or 5 axes, the positioners help meet
Innovative Products of America® has introduced the requirements of modern automation systems.
3-in-1 Diamond Grinding Wheels. Available in 2 The positioners use one of two mechanical drive
and 3 in. dia., the wheels are used with high-speed systems depending on customer requirements.
die grinders. High-capacity, zero-backlash programmable cam
Each grinding disc features a diamond-abrasive systems create high accuracies and repeatability of 2
edge that lasts 20 to 60 times longer than tradi- to 3 arc-sec.
tional abrasives, according to the company. The For material shuttling and transferring, the com-
3-D coating allows back cutting, gully grinding, pany has engineered a multiaxis positioning system
and bead finishing in areas other grinding wheels that uses a high-precision helical rack and pinion
cannot access. covering any distance.
Innovative Products of America, www.ipatools.com LazerArc, https://lazerarc.com
ELECTRODES DESIGNED
FOR TUBE WELDING
Gesellschaft für Wolfram Industrie
mbH has developed two new Orbistar
electrodes for orbital, tube, and circu-
CALL US TODAY lar welding.
TO FIND AN AUTHORIZED Comprising rare earths, the WS2
CK WORLDWIDE DISTRIBUTOR Witstar electrode offers durability
for tube welding applications. As
NEW for 2018! an alternative, the WLa 20 electrode
CK UltraTIG Series is suitable for working with frequent
ignition sequences. It is designed
for low currents and for working with
thin-walled tubes.
Process-specific alloys and cus-
tom dimensions also are possible,
1.800.426.0877 including angled electrodes up to a
diameter of 0.13 in. for interior welds
in tubes.
www.CKWORLDWIDE.com Gesellschaft für Wolfram Industrie mbH,
www.wolfram-industrie.de

PRODUCT NEWS
FLAP DISCS REMOVE MATERIAL QUICKLY

The patented POLIFAN®-STRONG flap discs from PERCUSSION WELDING MACHINE INTRODUCED
Pferd remove more material in less time than most Straus-Artys offers a percussion welding machine, providing weld-
other consumable abrasives for angle grinders, ac- ing time of about 10 ms and weld current of up to 100 kA. During
cording to the company. Featuring an extended flap the process, a joint is produced by a rapidly ignited arc and by
design for consistent, aggressive grinding, the discs the force which is generated by an electromagnet. Only one 50-
are suitable for use in steel construction, foundries, Hz half-wave is used for the actual welding process.
shipbuilding, automotive, tank construction, fabrica- The machine handles materials with high electrical and thermal
tion, and pipeline work. conductivity, as well as workpieces with large cross-section and
The coated flaps are produced with zirconia-alu- thickness differences.
mina abrasive, available in 36 grit for coarse grinding This method is suitable for materials that can be processed
of steel and weld seams or 50 grit for chamfering and on conventional resistance welding machines, as well as copper,
deburring. The discs are available in 4½, 5, and 7 in. tungsten, silver, molybdenum, nickel, and their alloys; workpieces
dia. with plain 7⁄8-in. bore or 5⁄8–11 threads. produced by powder metallurgy; and high-melting materials.
Pferd Inc., www.pferdusa.com Straus-Artys Corp., www.straus-artys.com

PRODUCT NEWS
PIPE WELDING CLAMP ENABLES GAS MANAGEMENT SYSTEM DESIGNED

FAST SWITCHING BETWEEN FOR INDUSTRY 4.0
DIFFERENT PIPE SIZES Abicor Binzel has released the EWR 2/EWR 2 Net gas
RIDGID® has introduced the Quick-Acting Pipe Weld- management system. It features a network-compatible
ing Clamp, designed for fast setup and alignment of software integration for real-time gas use monitoring
pipe. The welding clamp comes in two sizes for pipe and measuring.
from 2 to 6 in. and 41⁄2 to 12 in. Designed and built for Industry 4.0, the system uses
Both sizes feature quick-release buttons and Ethernet and CAN to connect to any business’s local
integrated handles for fast adjustment and simpli- area network to perform data logging of gas usage
fied switching between pipe sizes. They also include for manufacturers and have its parameters adjusted
spring-loaded winged set screws for three-point align- remotely. A single software program can access and
ment and an integrated size gauge for pipe measure- monitor gas usage for any number of the gas manage-
ment. ACME threaded screws transmit ample clamp ment system units.
force, while the heavy-duty steel construction is built The system uses quick-action frequency valves to
to withstand rugged job site applications. regulate the flow of gas in relation to the weld current.
RIDGID Inc., www.ridgid.com Abicor Binzel, www.binzel-abicor.com
THE
For additional information, please contact Foster Printing Service at Mossberg & Company Inc., the official reprint provider for The WELDER.
Reprints are ideal for: Custom reprint products of articles

New Product Announcements and features from The WELDER
Today create powerful marketing tools
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To place a classified ad in
The WELDER,
John Mathews
815-227-8219
johnm@thefabricator.com
ADVERTISERS INDEX
A.C.T. Dust Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 G A L Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
www.actdustcollectors.com www.galgage.com
Arcos Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
www.arcos.us Heck Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
www.heckind.net
ARKU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
www.us.arku.com Hobart Institute of Welding Technology . . . . . . . . . . . 10
www.welding.org
Bluco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
www.bluco.com
Hougen Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C K Worldwide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 www.hougen.com
www.ckworldwide.com
Kentek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CS Unitec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.kenteklaserstore.com
www.csunitec.com
Diamond Ground Products . . . . . . . . . . . . . . . . . . . . 11,13 K.I.W.O.T.O., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

www.diamondground.com 269-944-1552
ESAB Welding & Cutting . . . . . . . . . . . . . . . . . . . . . . . . 52 MITUSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

www.esab.com
www.mitusaproducts.com
Fabricators & Manufacturers
Associaton International . . . . . . . . . . . . . . . . . . . . . . . . . 31 OTC Daihen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
www.fmanet.org www.daihen-usa.com
FABTECH® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insert,7 PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

www.fabtechexpo.com
800-342-9015
Foster Printing Service
at Mossberg & Company Inc. . . . . . . . . . . . . . . . . . . . . . 48 Select - Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
www.fosterprinting.com 1-800-341-5215
The WELDER (ISSN 2576-0939) is published bimonthly by FMA Communications Inc., 2135 Point Blvd., Elgin, Illinois 60123. The
WELDER is circulated free upon request to those who qualify and who are involved in welding and joining; subscription to all others is
$45.00 per year. International subscription is $75.00 per year. Periodical postage paid at Elgin, Illinois, and additional mailing offices.
POSTMASTER: Send change of address to The WELDER, 2135 Point Blvd., Elgin, Illinois 60123. Printed in the U.S.A. Copyright 2018 by
FMA Communications Inc. Reproduction in whole or in part without written permission of the publisher is prohibited. The WELDER is a
trademark of FMA Communications Inc. All rights reserved.

JIM’S COVER PASS
Jim Mosman, AWS CWI/CWE, is chair of the

industrial technology department at Odessa
College, Odessa, Texas, and member of The
WELDER Editorial Advisory Committee.
jimscoverpass.thewelder@gmail.com
Welding school or learning

on the job?
I am currently a junior in high school and taking welding classes. I am debating
whether I should go to a college to pursue my career in welding after I finish high
school. If I just go straight to work, will that affect my long-term career?
Huber Montoya
This has been on ongoing debate for as living. Narrow your choices down to the top
long as I can remember, and it’s something three or four schools.
that I experienced firsthand in my own life. I The next step is to visit these schools by
began welding my sophomore year of high making an appointment with the instructors
school, went to work for a couple years, then and touring the facility. If possible, plan your
realized I had a lot more to learn. I completed visit while classes are in session so you can
a nine-month trade school program and then observe student activities. Compare the lab
started my first real welding job. space, number of welding booths, and the
Speaking as a community college instruc- variety and quality of equipment available.
tor for the past 20 years, my initial recom- Find out what the instructor-to-student ratio is
mendation will always be for you to continue for an average class size. Ask about job place-
your education. However, there are many ment assistance or internship programs. Don’t
ways to accomplish this. Community colleges, be afraid to ask questions.
union schools and apprenticeship programs, Finally, make your decision based on
private trade schools, on-the-job training, and where you feel the most comfortable and
now even online courses and blogs all have excited after your visit. Once you determine
something to offer. The questions you should which school you want to attend, contact
ask yourself are how do you learn best and the admissions office and start that process
what are your career goals? I know just as as soon as possible. I have seen plenty of
many good welders who learned on the job students who waited until after classes began
as I do welders who earned a degree from to enroll only to be disappointed when they
welding school. found out the class was already full. If you
No matter your age or experience, if you have not decided before you graduate from
do decide to attend a welding school, there high school, make that decision now so you
are a few steps for you to consider. First, can begin in the fall or next class offering.
research the various schools in your area or In the end, no matter how you decide to
those that may interest you. Most schools begin your welding career, surround yourself
have course descriptions, degree plans, and with experienced welders who are willing to
instructor information available on their web- mentor you. Before you know it, you will be
sites. Be sure to compare cost and payment helping others learn.
options. If the school is away from home, find Welcome to this great industry. Work safe,
out the availability of housing and cost of and never stop learning.
THE

Supplying the World with
Stainless for over 90 Years…
Arcos Stainless Steel

Electrodes
Arcos produces a comprehensive • Flux cored wires for flat and

line of premium bare wire, horizontal or out-of-position
covered and tubular stainless steel alloy welding work, with or without shielding gas.
electrodes. Whatever your demanding application – from • Metal cored wires for use in GTAW, GMAW and
nuclear or military construction to power generation or submerged arc processes.
petrochemical plants, pipelines to car exhaust systems,
shipbuilding to paper production, and so many others – And, of course, all Arcos electrodes are backed by our
Arcos has the right stainless steel electrode to meet your experienced team of technical specialists and customer
exacting requirements. service professionals.
These outstanding, made-in-America Arcos electrodes For more information on the entire spectrum of
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consisting of austenitic, duplex and superduplex, 1-800-233-8460 or visit our website at www.arcos.us.
martensitic and ferritic grades and are manufactured
to your specific needs. They include:
• Covered electrodes in -15, -16 and -17
coating options.
• Solid wires for use in GTAW, GMAW and
submerged arc processes.

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Scottie Smith, 2018 Teacher of The Year

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THE REAL WORLD FOR WELDING PROFESSIONALS July/August 2018

Formerly Practical Welding Today

An official publication of the

JulAug18Welder.indd 1 7/9/18 9:38 AM

NEXT GENERATION STAINLESS

SelectAlloy Made in America_1_31_18.indd 1 1/31/18 1:18 PM

July/August 2018 / Vol. 1 No. 6

4 July/August 2018 The WELDER

JulAug18Welder.indd 4 7/5/18 4:02 PM

CC-GRIND® -SOLID SG HHH

Excellent stock removal with

PFERD INC. PFERD CANADA INC.

PFERD quality certified according to ISO 9001.

Ceramic, SOLID, PSF_theWelder_JulyAugust.indd 1 6/25/2018 3:55:07 PM

More than just a welding teacher

6 July/August 2018 The WELDER

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GOLF4MFG NBT Open Manufacturing DaySM

Pipe & Tube Memphis AWS Detroit Sheet Metal Welding

The FABRICATOR’s Technology Summit FABTECH®

A PUBLICATION OF BUSINESS PUBLICATIONS

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LZH, partners develop laser welding process for joining

beam welding process is a 3-D scanner partners remain safely connected.

ESAB GTAW/SMAW inverter receives Red Dot Award

Hypertherm named one of America’s best employers by Forbes

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Weiler partners with Workshops for Warriors to launch fundraising campaign

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WITH JUST Weld Mold Co.

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Bluco launches Advance Welding Flex-N-Gate to Retired Hobart

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It’s a typical May evening in Niceville,

“CAN I MAKE IT ON MY OWN?”

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Given the choice by his father to either continue his

“At Southern Union I was in my dad’s shadow.

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The Welder’s Playground is Smith’s

STARTING FROM SCRATCH

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It’s late May, and even though the program is

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Adding more filler metal is one

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