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METAL FABRICATION 101: The Essentials of a Quality-Controlled Welding Station

A welding station is a critical piece of equipment in any fabrication shop. Welding stations need to be well maintained for them to produce quality welds consistently. This blog post will discuss custom metal fabrication in Indiana Wiley Metal Fabricating Inc.

Select the Right Welders for Assembly

The welders used in the assembly process will be a major determining factor of the quality-controlled welding station. The type and size of metal being welded and what kind of joint is required all effect which welder should be chosen for any particular job. For example, if steel needs to be welded together with a fillet weld joint, the welder needs to handle both materials. The type of metal being handled will determine whether an arc welding process or a plasma cutting process would work best for any given application.

Follow Spatter Prevention Best Techniques

In any welding station, it is imperative that spatter prevention techniques are followed to ensure the quality of welds. The key to preventing spatter is how hot and fast a metal needs to be heated before being processed on the machine. If this step is not done correctly, there will be no way to control where melted pieces end. The best way to prevent spatter is by using the proper shielding gas, masking off any surfaces that shouldn't be welded, and following a cooling process.

Know How Safety Impacts Welding Quality

Safety is always the top concern in any fabrication shop. One of the most critical aspects of safety when welding is maintaining a proper distance between welders and other team members at all times. This will minimize the risk for injury should a spatter of molten slag fly back while welding and reduce fire hazards if flammable materials are nearby.

Although it is not always possible to control the environment around a welding station, staying safe does impact quality-controlled welds. For example, without proper ventilation in place for shielding gas emissions, there will be a buildup of poisonous gases, leading to nausea and vomiting at best or death at worst, keeping all equipment away from any.

Ensure Safety-Driven Quality Control

Quality control in a welding station is only as good as the safety standards put into place. Welders need to be aware of any hazards around them and take steps to reduce or eliminate their impact on quality welds. For example, if there are open flames nearby, this would require installing fire suppression equipment like an automatic sprinkler system for the welding station.

If the welders are not aware of any safety risks, then it is up to management or other team members to take care of these concerns before returning to the task at hand. Safety needs to be a top priority for quality control measures like layout and tool placement on the machine itself will work properly.

Qualified Suppliers and Fabricators

Many suppliers and fabricators will be happy to offer a quote for the required equipment for welding stations. Excellent supplier relationships can help make quality control in the welding station easier by supplying all of the key components needed from one source. This includes brackets, clamps, electrodes, cables, connectors that have been pre-cut, and other items.

 Proper Layout

A quality-controlled welding station should always include a layout designed to maximize the safety of those working in it. Welders need to reach all tools without any risk for injury, so they do not have to lean over or step on anything while using them. Tools also need secure storage when not in use and may need to be stored in a different location when not being used.

The layout should also provide easy access to the welder itself so that anyone can come in and start working on any project without having to go through an extensive setup process first.

Should be Clean

A quality-controlled welding station should be clean at all times. Any slag, spatter, or residue left on the machine after work will impact safety and contaminate welds if it comes into contact with them.

 Proper Tool Placement

The placement of any tools used in the welding station should be considered carefully. While every project is different, specific guidelines can help ensure safety and quality control for all welding machines. Tools like wire feeders and foot pedals need ample space around them to not accidentally get bumped or kicked during use without severe consequences.

A quality-controlled welding station incorporates all the safety measures necessary to ensure the welders are safe and maintain a high level of quality.

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