In the manufacturing industry, one job that stands out from the rest in terms of necessity is that of the welder. No matter what kind of building you are doing, having a welder on staff will ensure that your products made are correct and durable. However, these days, it can be hard to find high-quality people to put on your team, meaning that the state of your welds may be slipping to the point where there may even be some safety issues.
Today, we’re going to discuss why welding is such an important component of manufacturing, and what options you have to ensure that you’re getting the best results. Even if you can’t hire the person you want, there are other ways of ensuring that you continue to produce the best standards for your products.
The Importance of Welding in Manufacturing
Virtually every industry relies on welding to function. Whether it’s making cars, ships, high-rises, or consumer goods, welders help create the world in which we live. Unfortunately, the demand for qualified applicants is not keeping up with demand, which is why it’s so imperative to find new solutions to fill in the gaps.
While automation can certainly help out in this regard, there is no real replacement for having a trained person able to do custom welding on hand to make your products to specification. Robots may be fast, but they can’t guarantee their work, and they can’t adapt to new situations.
What Makes a High-Quality Weld?
Three primary components are needed to ensure that your welds are as strong and reliable as they need to be. Let’s take a look at each part to understand how it all comes together.
Certified Welder
If possible, you will want to find someone who has been certified by the American Society of Mechanical Engineers (ASME). We’ll dive into what they do in a little bit, but essentially this certification ensures that the work performed will be of the highest quality.
Weld Inspector
Although inspection of each weld is necessary, that is not all that an inspector does. He or she is also responsible for ensuring that the welding environment is conducive to creating high-quality work, as well as providing the necessary tools to get the job done. Simply put, if you don’t have an inspector on site, it will be much harder to guarantee the quality of your work.
Stress Relief
When welding, it’s imperative that you keep the metal hot until the piece is ready to be cooled. If it cools off too fast, then it will disrupt the integrity of the metal and could lead to problems down the line. As such, it’s crucial that each weld undergoes stress relief, which is when you use hot air or electricity to keep the metal warm until the time is right.
Dangers of Low-Quality Welds
For the most part, these are the kinds of flaws you see in bad welding jobs. First, there are planar defects, which can include cracks and improper fusion and penetration. These are the most severe problems as they can diminish the integrity of the metal and cause it to break.
The second kind of flaw that is common is volumetric, which means that the weld is too thick, too porous, or contains extra slag. While these issues may not be as dangerous as planar flaws, they can require additional cleanup, which takes time and labor.
Finally, the last type of welding flaw is in the shape, which means that it could be misaligned or have an incorrect profile. Again, this may not affect the strength of the weld, but it could require revision and cleanup, which again diminishes your production load.
Benefits of High-Quality Welding
Better Reputation
Since your materials will be stronger and last longer, your company will be held in higher esteem. Your clients will appreciate the attention to detail and will be more likely to recommend you.
Save Time and Money
Since you don’t have to worry about cleaning up or fixing welds after the fact, you can improve your bottom line by making your production line much more efficient. Starting with higher quality welds will ensure that you can spend less time on inspection and more time on manufacturing.
Less Risk
Depending on the kinds of products you’re producing, a bad weld can be a devastating thing. If one of your pieces breaks or comes apart due to a bad job on your end, it could be dangerous for your clients. In the end, it can also spell disaster for your brand.
Outsourcing Your Welding
Because there are so many different components needed to ensure the quality of your welding, you may not be able to guarantee such conditions will be met on site. Thus, your best bet will be to find a custom welding service that can meet your product specifications and deliver consistent results.
ASME Certification
For best results, find a welding service that uses ASME certified welders. This organization oversees the quality of craftsmanship from each worker, and inspect the following criteria.
- Welding process
- Thickness
- Metal type
- Joint design
- Code compliance
- Position
The Society makes sure that each member performs well in a variety of ways, thereby ensuring that each weld is up to their standards.
Consistent and Quality Welding
If you’re interested in finding a local metal fabrication shop that can weld to your specifications, deliver fast and efficient results, and guarantee their work, then contact us! We have some of the best welders in the country, and are committed to delivering the best quality custom welds possible.