The resistance welding industry has evolved significantly over the last five years. Factors such as a widened application scope, advancements in technology, and improvements in skill acquisition have all impacted the sector. But all these almost came crumbling down last year at the peak of the COVID-19 pandemic.   

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Welding is a potentially hazardous workplace occupation. Annually, almost half a million welders in the United States are exposed to health and safety risks. From resistance welding and spot welding to flash welding and butt welding, safety measures and health protocols are put into place to ensure the safety of these workers. 

However, when these safety protocols are ignored or not followed fully, the risk of accident or injury goes up dramatically. The list of potential dangers is extensive: electrocution, asphyxiation, and fire- and electrical-related risks to name a few. At Tuffaloy, we believe in a safe and productive workplace. So, we have compiled a list of helpful reminders to keep the workplace safe. 

Here are the 7 most commonly overlooked safety protocols for welders:

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Flash welding is a popular resistance welding technique that involves joining two pieces of metal together using an electric arc. This technique is applicable for users in the metal-making industry.

It has become one of the popular methods for welding steel but also for nickel, aluminum, and titanium alloys. These metals are important for manufacturing sectors such as automotive, aerospace, heavy equipment, and more.

This blog post will go into detail on what flash welding is, the process of doing it, and why it's essential in the manufacturing industry.

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Many welding companies focus on getting their welding equipment and consumables at the best possible prices in a quest to reduce the cost of welding. While this is admirable, the focus should be on the big picture, which is getting productivity savings. By reducing costs in welding operations, the company can realize productivity savings year after year, even when the prices of consumables and equipment go up.

Cost-cutting measures in operations that don't compromise output quality are beneficial to a business. There are several factors ranging from consumables use to operational efficiency that can significantly reduce or increase the cost-effectiveness of a welding project.

This article will share the top five ways that we found helpful in significantly reducing costs in welding operations and realizing productivity savings.

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What is a weld nugget?

In resistance spot welding, “weld nuggets” are areas on the base material that are formed where the two metals are joined. The intense heat and sometimes low force of the welding process usually causes a depression or dimple.  There may be some material build-up around the edge of the weld site.  Analyzing and measuring nuggets after a weld is essential to keeping equipment operating in peak condition. They are useful in determining if the welding process is experiencing any irregularities and for determining the strength of the weld itself. The process for measuring nuggets is standardized across the industry. This enables manufacturers, suppliers and distributors to all have a clear picture of what’s going on behind the scenes.

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In all walks of life, using the correct tool for the job is an essential part of making your work easier, more efficient, and more effective. Welding is no exception to this rule, as evidenced by the abundance of forms and techniques involved in the process. While many types of welding appear similar on the surface, they vary widely in the processes they use to achieve fusion and the results they can produce. Today, we’ll talk about MFDC welding, and the potential benefits it provides to companies who choose to implement MFDC welding technology.

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Resistance welding, while being a subset of welding practices itself, is a fairly broad category. Many different variations of resistance welding are needed to apply the correct forces to the correct places in different situations. One of the most common variations of resistance welding used in manufacturing facilities is projection welding. We thought it might be useful to give some background information on what the process of projection welding entails, how it is used, and why. (Don’t worry, we’ve included pictures.)

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Welding, in all its forms, requires precision and patience. Issues that plague manufacturers can usually be sidestepped through adherence to checklists and careful maintenance, but sometimes problems arise despite our best-laid plans. We’re here to help you troubleshoot potential issues with your welds, inform you of why these defects arise, and what you can do to fix and/or prevent them. 

In a study of common welding defects and causes of poor weld quality, the most common factor by far was fixture errors, but issues can arise from the power supply, part geometry, and a number of other variables. Some of the more common ones are listed below.

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