How to Perfect Your MIG Welding Techniques

Want to perfect your MIG welding technique?

Then here is what you need to know. The reality is there are only 4 main techniques used:

  • Side to side
  • Whipping
  • Circles
  • Weaving

Guess what? None of these effect the quality as much as:

  • Joint preparation
  • Machine set-up
  • Getting comfortable

Most welders get so caught up in techniques that they over look the basic foundations of preparation. Once you spend enough time practicing your eye and hand coordination will do all of the work!Joint preparation

MIG welding requires a clean joint! If you have rust, mill scale, moisture, oils, paints or any substance that is not clean shiny metal then there is no welding technique that can help you! Remember welding is about following procedures and there is nothing more important then joint preparation. The World’s best welders cannot make a decent weld if the joint is not properly prepared. Take a robot that produces x-ray quality welds and then add a little grime to the weld area and all of a sudden that robot won’t be able to make a half decent weld!

If you don’t prepare your joint properly you will end up doing twice the work in repairs and it will never look right.

Machine set-up

Machine set-up is the most important part for producing a good weld. Voltage and wire feed speed can make or literally break a weld. When learning how to weld the most important exercise you can do is learn how to set-up your machine. Better yet try a new machine every day you weld so you force yourself to learn proper machine set up. A good exercise is to take the MIG gun and weld on a scrap piece of metal without looking. The sound alone can tell you if your machine is set right. squeeze the trigger and listen. You want the sound of an egg sizzling on a hot frying pan. Play with both the voltage and wire feed speed until you master every combination possible. Don’t be scared and take some risks! Thats the only way you will learn. On a side note every welding machine runs a little different. You need to learn how to adapt.

Getting comfortable

When it comes to the actual welding technique there is one rule you need to follow! Get comfortable! Lean and brace yourself so your hands are rock solid. If you need to tack on a piece of metal to lean on then do that. I like to keep a channel lock that I use as a shelf to lean on. As time goes by and you break a 1000 hours of practice you will learn your body’s ability. For example when I weld regularly I can weld overhead left and right handed without looking and produce a picture perfect weld. When I started I could barely keep the arc lite because my arms would fall from the gravity pulling on them.

In the end it does not matter how skilled you are because you still need a clean joint, the right voltage and wire feed speed settings with the comfort to steady your body and focus on your eye and hand coordination.

5 Different Types of Printed Circuit Boards

A printed circuit board (PCB) is a standard component in many different electronic gadgets, such as computers, radars, beepers, etc. They are made from a variety of materials with laminate, composite and fiberglass the most common. Also, the type of circuit board can vary with the intended use. Let’s take a look at five of the different types:

Single sided – this is the most typical circuit board and is built with a single layer or base material. The single layer is coated with a conductive material like copper. They may also have a silk screen coat or a protective solder mask on top of the copper layer. A great advantage of this type of PCB is the low production cost and they are often used in mass-produced items.

Double sided – this is much like the single sided, but has the conductive material on both sides. There are many holes in the board to make it easy to attach metal parts from the top to bottom side. This type of circuit board increases operational flexibility and is a practical option to build the more dense circuit designs. This board is also relatively low-cost. However, it still isn’t a practical option for the most complex circuits and is unable to work with technology that reduces electromagnetic interference. They are typically used in amplifiers, power monitoring systems, and testing equipment.

Multi-layer – the multi-layer circuit board is built with extra layers of conductive materials. The high number of layers which can reach 30 or more means it is possible to create a circuit design with very high flexibility. The individual layers are separated by special insulating materials and substrate board. A great benefit of this type of board is the compact size, which helps to save space and weight in a relatively small product. Also, they are mostly used when it is necessary to use a high-speed circuit.

Flexible – this is a very versatile circuit board. It is not only designed with a flexible layer, but also available in the single, double, or multi-layer boards. They are a great option when it is necessary to save space and weight when building a particular device. Also, they are appreciated for high ductility and low mass. However, the flexible nature of the board can make them more difficult to use.

Rigid – the rigid circuit board is built with a solid, non-flexible material for its layers. They are typically compact in size and able to handle the complex circuit designs. Plus, the signal paths are easy to organize and the ability to maintain and repair is quite straightforward.

Plastic Injection Molding In Manufucturing

Injection molding is an essential stage in the manufacturing of many materials that are made from their molten forms. In this process, the raw form of the object to be made are carefully put under high temperatures to melt and then injected into a mold and during the solidification process, the mold takes the desired shape.

Examples of materials that are used in this process are; plastics commonly known as thermoplastic and other polymers, glasses, metals in a process known as die casting and elastomers. Many manufacturing companies carry out this process since it is used in the manufactures of things such as home appliances automotive, parts, among many other daily essential gadgets that we come across.

What sets Injection Molding Manufacturers apart?

Despite such a step being the only way manufacturers get their end product, variations do occur and the following several aspects are the reason this happens.

The best companies always keep up with the technology; this has greatly affected the quality of those that have adamantly refused to embrace it. There are new and faster ways of doing things as opposed to how they used to be done, and therefore quality and customer preference has improved with technology.

Manufacturers require a dedicated team of engineers who design products that are in compliance with the law and those that are self-marketing. This is a huge standard that has widened the gap between different manufacturers.

There is the standard way of doing things such as mixing of the right materials in injection molding plant for one to get the right end product. The cost of these raw materials may be costly but only the best companies will ensure this is not a reason to compromise on their product.

A team of dedicated individuals, this allows minimal supervision and encourages accountability; hence everything is made with the right amount of precision, maintaining a high-quality product.

Manufacturers have always learned to maintain such an impressive portfolio by ensuring they do timely prototyping, lagging at this has consequently affected the performance and the overall rating of any company. Injection molding companies are typically supposed to prototype their product before the actual manufacture to ensure they get the desired product when the process commences.

Conclusion

This crucial process carries the weight when we come to the manufacturing of any product, and thus observing such guidelines as the ones that have enabled companies to scale big heights is encouraged. Take time to research on those that are highly ranked and have gotten accreditations from the manufacturing authorities and have great products in the market.

Oil Purification Systems and Its Applications

Oil purification systems are technology-based solutions for industries that are affordable and, in some cases, even bring in revenue by lending them to other companies for a price. It is a green technology which is barely getting itself noticed or brought to the focus of major industrial sectors. The problem is that people don’t realize that oil doesn’t die. It is merely contaminated and there are ways to get it purified or even recycled. Contaminated oil that infiltrates the ground can penetrate aquifers which supply drinking water so therein lies heavy damage to environment and health risks.

A million gallons of water can easily be contaminated with the toxic waste that is produced by a single oil change. Even the Environmental Protection Agency has issued guidelines for managing, reusing and recycling used oil which is the need of the hour with global climate worsening. North Americans alone consume about 19 million barrel a day and waste oil is a major part of that figure. The industry accounts for almost half of the oil consumption. Waste oil is always handled as a hazardous material, depending on its chemical composition. Oil purification systems can help change things by recycling.

More than that, manufacturers of waste oil don’t see the savings involved so they won’t understand the need for oil purification. Till 2012, a measly five percent of industrial plants believed in restoring and reusing oil but due to awareness and research, these numbers have gone up considerably since then. Due to the financial gains of oil purification systems, the chain effect in saving costs is huge. For instance, factories and plants don’t have to pay for hauling waste oil, they can just recycle it.

Onsite oil purification impacts downtime. Whenever a plant is shut down for equipment repairs, thousands of dollars are lost per hour and failure’s main reason is contaminated oil. So, purification systems act like a dialysis machine for all industrial equipment. Wheeled and on carts, they are easily rolled over to equipment like turbines and pumps which are hooked up to the system. The process gets the oil cleaned of contaminants and renders its state to its almost-original condition thereby lowering break-rates of downs and repairs. Various industries have now begun to realize that purification systems can save them vast amounts of money in different ways.

For instance, solid waste management operators can use the system for their fleet of trucks and vehicles to extend their life. Cement factories are another example of using oil purification systems for their heavy machinery. Large power plants and grid stations use turbines and transformers which varnish that is caused by moisture contamination. Processing plants and production facilities all use oil systems for their operations on a large scale. Others like compressor plants in oil and gas sectors cannot tolerate contamination otherwise gas flow for energy to the consumer would be badly affected.

Developing Innovative Products

Phase 0: Feasibility Analysis

The goal of this phase is to identify existing technology to achieve the intended high-level function. If technology can be purchased as opposed to developed, the scope of subsequent development phases changes.

Simply put, product development companies research and assess the probability that the current technology can be used to reach the intended functionality of the product. By doing this, the development efforts are reduced, which in financial terms represent a great reduction in development costs.

Moreover, if the technology is not yet available, then the assessment can result in longer development cycles and the focus moves into creating the new technology (if humanly possible) that can accomplish the functionality of the product.

This is an important part of the in any product development process because it is safer and financially responsible to understand the constraints that a product can have prior to starting a full development cycle. A feasibility study can cost between 7 -15 thousand dollars. It might be sound very expensive for some, but when it is much better than investing $100k+ to end up with a product that no manufacturer is able to produce.

Phase 1: Specification or PRD (Product Requirements Document) development

If your product is feasible, congratulations! you are a step closer to creating your product and you can move into documenting what is going to go into the product itself, aka the guts (product objective, core components, intended end-user, aesthetics, User interphase, etc).

In this phase, product design and engineering focus on documenting the critical functionality, constraints, and inputs to the design. This is a critical step to keep development focused, identify the high-risk areas, and ensure that scope creep is minimized later.

This document will help you communicate the key features of your product and how they are supposed to work to all members of your team. This will ensure that you keep everyone involved on the same page.

Without one, you are more likely to stay off track and miss deadlines. think about the PRD as your project management breakdown structure (BDS)

Phase 2: Concept Development

Initial shape development work identifies options for form, as well as possible approaches for complex mechanical engineering challenges. Initial flowchart of software/firmware also happens here, as well as concept design level user interface work. Aesthetic prototypes may be included in this Phase, if appropriate. Prototype in this phase will not typically be functional.

Phase 3: Initial Design and Engineering

Based on decisions made at the end a concept development phase, actual product design and engineering programming can start. In this phase, Level 1 prototypes are often used to test approaches to technical challenges.

Phase 4: Design Iteration

This part of the project is where we focus on rapid cycles, quickly developing designs and prototypes, as the depth of engineering work increases. This phase can include Level 2 and 3 prototypes, typically through multiple cycles. Some products require as many as twenty prototype cycles in this phase. Others may only require two or three.

Phase 5: Design Finalization / Optimization

With all assumptions tested and validated, the design can be finalized and then optimized for production. To properly optimize for production, product design and engineering teams take into account the target production volumes, as well as the requirements of the manufacturer. Regulatory work may start in this phase.

Phase 6: Manufacturing Start and Support

Before production starts, tooling is produced, and initial units are inspected. Final changes are negotiated with the manufacturer. Regulatory work also should wrap up in this phase.