Cost Savings Analysis

There are many ways to reduce costs in welding operations. Here are 11 ways to get you started:

• Eliminate Overwelding – Make sure welds are properly sized by following what is called out on the print. Don’t have prints? Develop them! The savings can be huge.
• Reduce the amount of reinforcement – Multiple pass welds on a groove joint typically end up with a certain amount of reinforcement. The goal is to be just above flush to prevent under fill. However, a 1/8″ reinforcement will not be better than a 3/32″ or even a 1/16″ in most cases.
• Use proper polarity – In applications were penetration is not important or desired, such as hardfacing, use DC- to achieve greater deposition rates.
• Reduce gaps - Gaps increase the volume of weld needed.
• Control flow rates – For processes that require shielding gas make sure no more flow than necessary is used. Too much flow will waste gas and can even create weld defects.
• Increase electrode diameter - Whether you are stick welding or mig welding, consider using a larger electrode to achieve higher deposition rates.
• Consider intermittent instead of continuous fillets
• Select the right process - Don’t TIG weld if MIG will do. Sticking? Can you use a wire process?
• Properly position the work for optimal efficiency – ideally we want to weld in the flat or horizontal position. Welding out of position (vertical up, overhead, 3 0’clock, etc.) reduces deposition rates because we are limited in puddle size.
• Use fixtures
• Use procedures and processes that eliminate spatter – Consider using 90/10 gas instead of C25 or 100% CO2. Consider pulse welding instead of CV welding.

Contact Arco Welding Supply for a more comprehensive analysis of how you can reduce your overall welding cost!!