Here’s How Welding Impacts the Strength of Structures

Posted on November 4, 2024November 4, 2024 by ER Machining

Welding plays a pivotal role in constructing everything from buildings and bridges to vehicles
and pipelines. It’s a process that joins metals by applying heat, pressure, or both, fusing
materials to form a strong bond. In structural applications, the strength, durability, and safety of
the final product rely heavily on the quality and integrity of the welds. This article will explore
how welding services impacts the strength of structures, the factors that influence weld strength,
and why proper welding techniques are essential in construction and manufacturing.

1. The Basics of Welding and Structural Strength

Welding services involve melting the edges of two pieces of metal and bonding them together
when cooled. This process creates a joint that should ideally be as strong as the base materials
themselves. When done correctly, welding companies can create structures that withstand

heavy loads, extreme weather, and constant wear. However, achieving this strength depends
on numerous factors, such as the type of weld, the choice of materials, the skill of the welder,
and the specific technique used.
In structural applications, a weld must meet stringent standards because any weakness in the
weld joint can lead to structural failure. For instance, the collapse of a building or a bridge could
have catastrophic consequences. This is why industries prioritize high-quality welds to ensure
maximum durability and strength in their projects.

2. Types of Welds and Their Impact on Structural Strength

Different welding techniques offer varying levels of strength and suitability for specific
applications. Here’s a look at some common welding methods and how they impact structural
strength:

Shielded Metal Arc Welding (SMAW)
Also known as stick welding, SMAW is one of the oldest and most widely used welding
methods. It’s relatively simple but effective for heavy-duty applications like construction and
pipeline work. SMAW produces a strong bond, especially for thicker metals, but requires skill to
avoid defects like slag inclusions or porosity, which can weaken the weld and reduce structural
integrity.

Gas Metal Arc Welding (GMAW)
Commonly known as MIG (Metal Inert Gas) welding, GMAW is a popular choice for its versatility
and ease of use. This method produces clean, precise welds suitable for thin metals and
complex structures. However, MIG welds are often less strong than those created by other
techniques like TIG, making them ideal for lighter structures but not always the best choice for
heavy-duty structural applications.

Gas Tungsten Arc Welding (GTAW)
Known as TIG (Tungsten Inert Gas) welding, GTAW produces high-quality, precision welds. It’s
often used in applications requiring extreme strength, such as aerospace and automotive
industries, as well as in structures that need to endure high stress. TIG welding produces very
strong bonds, but it’s time-consuming and requires significant skill, which can make it more
expensive for large structural projects.

Flux-Cored Arc Welding (FCAW)

FCAW is commonly used for heavy structures that require strong welds and are exposed to
challenging environments. This method is particularly suitable for thicker sections of steel and
can be used outdoors, making it a preferred choice for structural welding services in
construction. FCAW provides high-strength welds but, like SMAW, must be performed skillfully
to avoid defects.

3. Factors That Affect Weld Strength

While choosing the right welding technique is essential, there are several other factors that
influence the strength of a weld and, in turn, the strength of the entire structure. Understanding
these factors can help manufacturers and engineers ensure that their structures are safe and
durable.

Material Compatibility
The strength of a welded joint depends on the compatibility of the base metals being joined.
Some metals, like certain types of stainless steel and aluminum alloys, require specific
techniques and filler materials to achieve a strong weld. Incompatible materials can lead to
weak joints and reduce the overall strength of the structure. For instance, welding services for
dissimilar metals can create residual stresses that weaken the bond unless special filler metals
are used.

Proper Heat Control
The application and control of heat play a significant role in determining the quality of a weld.
Too much heat can cause warping, excessive melting, and microstructural changes that weaken
the weld, while insufficient heat can lead to a lack of fusion between the base materials.
Experienced welders know how to control heat input to avoid defects and ensure that the weld
joint maintains its strength under stress.

Weld Geometry
The shape and size of a weld joint also impact structural strength. A properly designed weld,
such as a full-penetration weld, provides maximum strength because it creates a continuous
bond between the two metals. In contrast, a partial-penetration weld may only provide
superficial bonding, making the structure more susceptible to failure under heavy loads.

Presence of Weld Defects
Defects such as porosity, cracks, slag inclusions, and undercuts can compromise weld strength
and, consequently, the strength of the structure. Porosity, for instance, creates air pockets

within the weld that weaken the bond. To minimize the risk of defects, skilled welders follow
rigorous preparation and inspection protocols to ensure high-quality welds.

4. How Welding Impacts Structural Durability and Safety

In many ways, welding directly affects the durability and safety of structures. Quality welding
shops in Houston TX can enhance a structure's lifespan, allowing it to withstand various
stresses over time without significant degradation. This durability is crucial in applications such
as bridges, skyscrapers, and pipelines, where failure is not an option.
A well-executed weld provides the strength and resilience necessary to endure environmental
stresses, such as wind, rain, and seismic activity. Welding service can also improve a
structure’s resistance to corrosion, especially when protective coatings are applied after
welding. Corrosion-resistant welding is essential for infrastructure exposed to moisture or
chemicals, as rust and corrosion can significantly weaken the structure over time.

5. Inspection and Testing: Ensuring Weld Quality

To ensure weld strength and safety, industries rely on stringent inspection and testing
standards. Non-destructive testing (NDT) methods like ultrasonic testing, radiographic testing,
and magnetic particle testing are used to inspect welds for internal and surface defects without
damaging the joint. These tests allow engineers to assess weld quality, identify any flaws, and
determine if repairs or additional reinforcements are necessary to maintain structural strength.
Visual inspections, hardness tests, and tensile strength tests are also commonly used to
evaluate weld quality. These testing methods provide valuable insights into a welding ability to
withstand stress, ensuring that only strong and reliable welds are used in critical structural
applications.

Conclusion
Certified welding services are a crucial factor in determining the strength, durability, and safety
of structures. From choosing the right welding technique to managing heat control and ensuring
defect-free welds, many aspects contribute to creating strong, reliable bonds that can withstand
the demands of structural applications. By adhering to best practices in welding, industries can
build structures that are not only functional but also safe, durable, and capable of enduring the
test of time. Whether constructing a skyscraper, bridge, or pipeline, the strength of every weld
contributes to the strength of the entire structure.

The Role of Automation and Robotics in Modern Welding Shops

Posted on April 5, 2024 by ER Machining

In the ever-evolving landscape of manufacturing, automation and robotics have revolutionized the way welding is done. Modern welding shops are increasingly turning to automation and robotics to improve efficiency, quality, and safety in their operations. In this article, we’ll explore the role of automation and robotics in modern welding services and how they are transforming the welding industry.

Increased Efficiency

One of the primary benefits of automation and robotics in welding shops is increased efficiency. Automated welding systems can work continuously without the need for breaks, resulting in higher productivity and faster turnaround times. Additionally, robots can perform welding tasks with a high degree of accuracy and repeatability, leading to fewer errors and rework.

Improved Quality

Automation and robotics have also led to improved quality in welding services and operations. Robots can consistently produce high-quality welds, ensuring that each weld meets the required specifications. This is especially important in industries where weld quality is critical, such as aerospace and automotive manufacturing.

Enhanced Safety

Safety is a top priority in welding shops, and automation and robotics have helped improve safety standards. By automating welding processes, welding companies can reduce the risk of injuries to workers from exposure to hazardous materials and high temperatures. Additionally, robots can work in environments that may be too dangerous for humans, further enhancing safety in welding operations.

Cost Savings

While the initial investment in automation and robotics can be significant, the long-term cost savings can be substantial. Automated welding services can work faster and more efficiently than manual labor, leading to lower labor costs over time. Additionally, robots can reduce material waste and rework, further lowering costs for welding shops.

Flexibility and Adaptability

In modern welding services, robots are highly flexible and adaptable, capable of performing a wide range of welding tasks. They can easily switch between different welding processes, materials, and weld configurations, making them ideal for high-mix, low-volume production environments. This flexibility allows welding shops to respond quickly to changing customer demands and market trends.

Remote Monitoring and Control

Automation and robotics have also enabled remote monitoring and control of welding operations. Welding shops can now monitor their automated systems in real-time from anywhere in the world, allowing them to quickly identify and address any issues that may arise. This remote monitoring capability improves efficiency and reduces downtime in metal welding services.

Environmental Benefits

Automated welding systems are also more environmentally friendly than traditional welding services methods. Robots produce less waste and consume less energy than manual labor, reducing the carbon footprint of welding operations. Additionally, robots can be programmed to optimize welding parameters for maximum efficiency, further reducing energy consumption and waste.

Conclusion

Automation and robotics have revolutionized the metal welding service industry, providing welding shops with increased efficiency, improved quality, enhanced safety, cost savings, flexibility, adaptability, remote monitoring and control, and environmental benefits. As technology continues to advance, the role of automation and robotics in modern welding companies will only continue to grow, shaping the future of welding for years to come.

The Art and Science of Welding: A Comprehensive Guide by ER Machining

Posted on March 7, 2024March 6, 2024 by ER Machining

Modern society needs metal-fabricated objects and structures in some capacity in everyday life. Multiple welding techniques exist to suit the kind of metals to be joined together. The metal welding services and welding companies also consider the desired output or structure and the welder’s skill level. These skills and techniques matter because different metals, such as aluminum, steel, and copper, among others, have varying melting points.

ER Machining’s mission is to be the leading company when it comes to all things metal and fabrication in the Houston, Texas area. We have state-of-the-art machinery and are certified to provide certified welding services at our welding shops to meet your metal and fabrication needs promptly, and with professionalism.

The Importance of Welding in Industry

Welding plays a significant role in various industries on which the world depends, for example, aviation, automotive and construction industries, among others. More than 70% of fabricated works come directly from welding. Direct examples where vessel welding plays a role are, in road works, gates, fences, kitchen devices and ware, pipelines, vehicles, planes, space shuttles, and artillery, among others.

While these welding provisions may seem insignificant, the welding industry largely contributes to a country’s economy. The manufacturing industry, in which welding plays a huge role, accounts for 12% of GDP in the USA and employs over 12 million people (data from the American Welding Society).

With increased population growth comes an increased demand for commercial products and infrastructure produced directly or indirectly by the welding industry. It means the industry will contribute even more to the country’s GDP.

Understanding the Welding Process

Welding involves fusing two or more metals, plastic or wood (the original material to be used during welding services is referred to as filler or consumable). It forms a weldment (the resulting joint) from the parent material (the cojoined parts). The different types of welds include the slot weld, plug weld, full penetration weld, and partial penetration weld (partial joint penetration).

Welding methods

1. Gas Metal Arc Welding (GMAW/MIG)

It’s commonly found in construction and automotive settings. Here, a thin wire acts as an electrode to create an electric arc. It heats up as a welder feeds it through a welding instrument while using a shielding gas (carbon dioxide, argon, oxygen or helium) to keep the area free of airborne contaminants and works on stainless steel, copper, and nickel, among others.

2. Shielded Metal Arc Welding (SMAW/Stick Welding)

SMAW is a low-cost process that’s not so strong on the quality side. It’s popular among home-shop welders and uses a flux-coated electrode consumable in a manual two-handed process. It has similarities to the TIG method but melts the stick rod and flux coat to emit the gas that shields the welded section from contaminants.

3. Gas Tungsten Arc Welding (GTAW/TIG)

It’s most common for thin and non-ferrous metals. It’s an advanced welding form centred around patience, experience and skill. Its major difference from other methods is its use of a non-consumable tungsten electrode when forming the weld.

4. Flux Cored Arc Welding (FCAW)

FCAW is a distinct two-process welding method where the welder feeds wire continuously during the progression. In one part, shielding gas takes centre stage while in the other, self-shielding agents that are an offshoot of decomposed flux material within the wire enable the process. The latter enables outdoor welding and is typically used in construction due to its high speed and portability.

Others include; Submerged Arc Welding, Thermit Welding, Gas Welding, Forge Welding, Electron Beam Welding, Resistance Welding, Plasma Arc Welding, and Atomic Hydrogen Welding.

The importance of adhering to quality and safety standards in welding.

Adopting safety standards in producing quality welded material ensures the well-being of workers and end product consumers. Having strong welds that will not unexpectedly break, causing injuries is fundamental.

Quality means the aesthetics, which are crucial to consumers, are catered for as well since poorly welded products are easily noticeable. It also all but guarantees the performance, longevity and durability of a product, since the joints will withstand stress and tension easily.

Quality metal works also reflect well on the company that produces the work. Attention to detail, concern for customer wellbeing, regard for quality, taking pride in work done and great customer service are all essential in attracting and retaining customers.

Innovations in Welding Technology:

There is a rise in more efficient welding techniques that increase the speed with which tasks are completed. Robotic welding systems take the lead where the control offered by computers is leveraged to weld metals with enhanced precision and speed. It’s effective and facilitates welder wellbeing. Robotics, the cost-effective approach, will soon lead to the automation of the whole welding industry, eventually eliminating the human error element. It’s possible since the parts follow specific instructions from computer programs.

Laser welding tech is one of the latest advancements in the welding world. The laser beams rapidly melt the metal, fusing the target area as required. The high-precision method enables fine work with the most intricate of parts. It’s estimated to be up to 10 times faster than MIG welding. Since the heat used is moderate, it’s a popular form in medical and automotive work.

Large-format metal additive manufacturing and Robotic metal 3D printing are interchangeable terms that refer to Wire arc additive manufacturing. It is another breakthrough method that fuses automated MIG (metal inert gas) or laser welding with 3D printing. This modern approach has enabled the industrial sector to produce huge metal parts in reduced lead times while eliminating costly supply-chain challenges.

ER Machining and Welding:

At ER Machining, we have a team of certified welders {European Pressure Equipment Directive (PED), National Board Inspection Code (NBIC) and ASME Section VIII} that man the over 400 welding processes. We are committed to customer satisfaction through our modern welding solutions that surpass performance and quality expectations. TIG, MIG, Plasma arc, and Submerged Arc welding processes are our specialty. Our team has several welding credentials from different welding codes.

Environmental Consideration

Welding produces fumes from the metals, fillers, shielding gasses and fluxes, as well as debris and remains that become environmental waste and contaminants. To counter these, ER machining ensures the team cleans usable material of paints, oils and coatings before welding. This minimizes corrosion, rusting and environmental contamination. Where applicable, solvents are used to render these coatings inert and harmless to the environment.

Other than that, we recycle reusable parts, use automation, invest in energy-saving systems, use environmentally friendly energy sources, use fume extraction systems and choose less environmentally impactful processes (like the use of virtual reality in training, which we take seriously, new staff) and consumables. All this is possible while upholding quality standards and putting our clients first.