The extremely popular 2010 Fabtech  expo is right around the corner, and Miller Electric Mfg. Co. is introducing some really cool new products, including the new Titanium Series welding helmets as well as the new WeldX protective apparel (available at Arc-Zone.com).  And if you’re looking for other TIG related products to go with your Big Blue welder generator, be sure to check out Arc-Zone’s TIG parts and accessories.  And be sure to look for Joe Welder himself, who will be attending this year.

Miller Electric Mfg. Co. will showcase a wide range of new and popular welding products, technologies and safety accessories at the FABTECH 2010 show at the Georgia World Congress Center in Atlanta, November 2 – 4. Miller’s booth this year (#6811 in Hall C) will provide attendees with product selection clarity by featuring market specific solutions designed to address the specific needs and challenges of the manufacturing, fabrication, shipbuilding, construction and commercial welding markets.

• FILTAIR^™ SWX-Series wall-mounted fume extractor
• Big Blue^® 400 Eco Pro welder generator
• Titanium^™ Series heavy-duty welding helmets
• XR^™ Control push-pull wire feeders
• WeldX^™ protective apparel
• Dimension^™ NT 450 WCC

In addition those listed above, Miller will be unveiling several new products and technologies that increase welding productivity, reduce weld costs and improve application adaptability.

Miller’s TIG Solutions Marketing Manager, Brent Williams, will also be giving a presentation on the benefits of TIG inverter technology, and the advanced arc controls it offers, as it relates to aircraft engines and components. The presentation will take place from 4:05 p.m. to 4:40 p.m. on Wednesday, November 3.

Plus don’t forget to regularly check Miller’s social media outlets — YouTube, Facebook and Twitter — for regular updates, videos and special promotions from the trade show floor.

FILTAIR SWX

Miller’s new FILTAIR™ SWX Series of space-saving wall-mounted welding fume extractors, are available in either the self-cleaning SWX-S model or the disposable filter SWX-D model. SWX-Series extractors can be fastened to a variety of wall surfaces, allowing companies to improve air quality and protect employees without cluttering their shop floors.

Like the mobile FILTAIR™ MWX Series, the SWX-Series uses surface-loading nanofiber filters designed specifically to capture the 95 percent of sub-micron particles found in welding fumes, including hexavalent chromium and manganese. Because the nanofiber filters are “surface-loading,” they offer more holding capacity and less pressure drop than competitive, “depth-loading” fume filters.

The SWX-S and SWX-D provide 875 CFM (cubic feet per minute) airflow for excellent fume removal up to the maximum recommended hood distance of 14 in. from the welding arc. Designed for heavy-duty industrial use, both models are suitable for continuous filtration of Stick, flux-cored, MIG and TIG fumes. For added application flexibility, both SWX models are available with one or two extraction arms that come in lengths of 7, 10 or 12 ft.

Big Blue 400 Eco Pro

For pipe welding, structural steel, fabrication, field maintenance and repair applications, the new Big Blue^® 400 Eco Pro welder generator reduces fuel use up to 25 percent and is 44-percent smaller/41-percent lighter than other models with similar output.

Providing Stick, TIG, MIG, FCAW and CAC-A processes, the Big Blue 400 Eco Pro offers 5,500 watts of peak power — plenty to run lights, grinders and many electrical tools. Its Mitsubishi S4L2 Tier 4i compliant diesel engine is designed to run 10,000 hours before a major overhaul and produces 50-percent less noise than previous models.

Taking into account average diesel costs of $4.00/gallon and the habits of a typical user — 50 percent idle time, 40 percent at 150 amps, and 10 percent at 400 amps — a welder can save up to $1,990/year per machine in fuel costs without sacrificing performance.

Titanium Series Helmets

Miller’s new Titanium^™ Series offers a comprehensive choice of helmets to meet the daily demands of industrial welding applications. From standard passive to auto-darkening helmets, with one model featuring an integrated grinding shield, the Titanium Series redefines industrial welding protection through optimal comfort and performance.

Designed for industrial protection, performance and comfort, the Titanium Series is built upon a shell design that is lightweight for extended wear, provides excellent skin coverage, reflects radiant heat and features a quick-release front cover lens to reduce welder downtime.

The Titanium Series is available in three auto-darkening models, featuring auto-on/auto-off, grind mode, independent arc sensors, excellent low-amperage TIG performance (5 amps), magnifying lens holder and they all meet ANSI Z87.1-2003 (High Impact) standards. Also available is a shade #10 passive lens model that features a large, 16-sq.-in. lens.

XR-S/D Controls

Miller’s new XR™-S Control and XR™-D Control push-pull wire feeders feature upgraded point-of-use functionality and performance for a wide variety of aluminum MIG, Pulsed MIG and extended reach welding applications.

Weighing under 43 lbs., the XR-S and XR-D Controls provide a highly portable solution for working up to 135 ft. from the welding power source. An A/C variable speed, high-torque “push” motor responds in real time to the gun-mounted DC “pull” motor to provide true push-pull performance. This allows the welding wire to overcome bends and extreme angles when working in and around large weldments.

The XR-S Control provides a simple, intuitive design and basic functionality, featuring adjustable run-in, pre- and post-flow options and a digital wire feed speed display that allows the user to easily see and adjust wire feed speed with the turn of a dial.

For more advanced applications and increased point-of-use adjustability, the XR-D Control offers remote voltage control, programmable pre- and post-flow and manual start and crater control options.

For the ultimate in aluminum MIG welding technology, Miller offers its Aluma-Feed Synergic Aluminum Welding System, featuring built-in Pulsed MIG programs that set the optimal parameters for the most commonly used aluminum alloys. The Aluma-Feed’s synergic welding mode provides the simplicity of single knob control by automatically choosing the correct voltage and amperage when the welder selects the desired wire feed speed.

WeldX Apparel

Miller’s exclusive new WeldX^™ line of welding safety apparel uses a revolutionary new material that provides exceptional flame and spatter resistance and is 60 percent lighter than leather, resulting in reduced heat stress and operator fatigue.

Originally designed for military applications, the WeldX fabric uses a patented carbonized acrylic base fabric that is then strengthened for durability and treated with a compound that causes weld spatter and sparks to literally “roll off” the material upon contact.

Unlike leather, the WeldX fabric is easily washable and is guaranteed to retain its flame resistant qualities for the life of the garment.

Only available from Miller, the WeldX line of safety apparel includes traditional welding jackets, 1/2 length sleeves, aprons and cape sleeves with an optional bib.

Dimension 452 WCC

Ideal for shipbuilding, marine repair and other applications where the power source and wire feeder are separated by up to hundreds of feet, the new Dimension^™ NT 450 WCC multi-process welding system saves time and increases safety by reducing trips to the power source for parameter adjustment. It also reduces weld quality problems caused by “working around” improper parameter settings, and eliminates control cable set up, maintenance and repair costs.

Using the built-in WCC (Weld Control Cable) feature and a WCC-enabled voltage sensing wire feeder, welding operators can control voltage at the wire feeder, eliminating the need to travel to the power source for parameter adjustments. And, fewer trips to the power source means fewer potential accidents along the way.

Further, because they can control parameters at the wire feeder, operators are less likely to attempt to “weld through” improper settings, a practice that often results in structural and visual weld defects.

By eliminating the need for control cables the WCC feature reduces the time and expense associated with purchasing, repairing and maintaining control cables.

The Dimension NT 450 WCC’s Ez-Bind feature guarantees remote control operation with multiple power sources connected to the same workpiece.

These welding gear packs are going to be popular for Christmas so PRE ORDER your BSX Welder’s Helmet Bag / Gear Pack today!

BSX Welders GearPack / Helmet Bag is styled in black and gray with red accent piping–  AND it’s rugged making it a great way to Store AND Transport your welding gear.

This specialized backpack is constructed of high-quality materials and engineered with a quick-action HelmetCatch (which makes it easy to access your helmet). The side pockets fit two pairs of gloves, and the large storage area with rigid side walls  protects and stores your torch, and other tools–  and even your lunch box!

Roll to the jobsite, welding class or through the airport with the BSX Helmet Bag and you’ll be noticed!  We even joked around the office that this would make a great backpack for cycling to school (with a place to store your bike helmet) or the bowling alley (with a spot for your bowling ball)!

The exclusive quick-action HelmetCatch™ makes this gear pack stand out above all others. It introduces a secure 5-point rigging system and fast drawbridge action designed to make protecting your helmet a snap. The padded construction of the HelmetCatch™ helps protect the expensive lens from bumps and scratches, while the unique shape accommodates welding helmets of all sizes. The gear pack itself can be worn over the shoulders as a rugged backpack with fully adjustable ergonomic straps, or it can also be carried by its sturdy, rivet-reinforced top handle.

Constructed with rigid walls, the GB100 supports a welding helmet and heavy duty welding gloves on the outside, while leaving plenty of storage room within. The inside features pockets designed to organize hammers, brushes, tip cleaners, electrodes and more. A utility carabiner and a free lunch cooler are also included with the package.

Pre-Order your bag Today from  Arc-Zone– they’ll be available in December.  Just in time for the holidays.

Carlsbad, Calif.— Whether you’re using the Thermal Dynamics 2A, 3A, 4A and PWM300 Plasma Arc Welding Torches, setting up a new Plasma Arc Welding station, or optimizing your existing welding station, Arc-Zone.com’s Plasma Arc Welding Accessory Kits are fully loaded with a variety of performance proven parts.

Designed by Arc-Zone.com technicians, the kits allow you to fine-tune your existing plasma arc welding torch, or get your new torch dialed in and ready to weld.

Operations manuals often suggest options for various amperage settings, adjustments and top sizes. “The benefit of the Arc-Zone kit is that every part you need is stored in one convenient and rugged kit box,” says Jim Watson, founder and CEO of Arc-Zone.com. “From replacement shield cups, back caps, pre-ground electrodes, shield cup gaskets, to long tips you’ll have easy access to the parts you need to customize your torch, minimize downtime, and you’ll have the quality to minimize variables.”

Whether you’re ordering the standard kit or the deluxe kit, you’ll also get Joe Welder’s Guide to Optimizing Your Plasma Arc Welding Torch. And re-ordering parts for your kit is easy: each kit is labeled with a custom made lid card that identifies each component, and a super cool Weld Like A PRO™ sticker.

Founded in June 1998, Arc-Zone.com®, Inc. delivers proprietary, brand name and OEM replacement parts and accessories for GMAW, GTAW and Plasma Arc Welding and Cutting applications to customers worldwide.

Though not affiliated with Thermal Dynamics Corporation, Arc-Zone supplies OEM and high quality replacement parts manufactured to demanding specifications and engineered to be interchangeable with Thermal Dynamics® parts, are not OEM parts and are not endorsed by Thermal Dynamics®

For more information, visit the Arc-Zone.com web site at www.arc-zone.com, call 760-931-1500 or email sales@arc-zone.com.

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German welders + sausage + welding machine = Electric grill for men???

Adventurous Germans Grill Sausages with an Industrial Welder

“Eventually, the tube was so hot that the arc had to be shut down because the fat was on the verge of spontaneous combustion.”

By Vin Marshall  Posted 03.22.2010

Barbecue grills don’t typically require eye protection, but then, they’re typically not made from a giant TIG welder and an industrial sausage positioner either.

That’s something these Germans set out to change with the “Electric Grill For Men.”

What would you do if you needed to endurance-test a large industrial welding power supply?

You’d probably rig up something like the apparatus pictured here, in which a TIG welding torch draws a continuous arc along a slowly rotating piece of aluminum tubing mounted in a work positioner normally used for pipe welding.

As the long weld bead is laid down, the power supply is tested to verify that it can maintain its rated output and duty cycle without melting down. In the process, a great deal of heat is generated.

What would you do if you hated to see all of that heat going to waste? And furthermore, if you loved sausage?

CONTINUE READING ONLINE ->

Metal manufacturing workers use talents to transform scraps into art

By Rick Barrett of the Journal Sentinel
Posted: Feb. 8, 2010

When a piece of scrap metal falls to the factory floor at Wagner Companies, employee James Woggon may be close behind, snapping it up as material for his artwork.

So when thousands of small metal rings were going to be scrapped, Woggon used them – and a chair from the company cafeteria – to create a funky piece of patio furniture.

It was strictly for fun. Yet the talents of Woggon and fellow employee Jason Scott have not been lost on their employer, which manufactures things such as hand railings and snowplow parts. The two were hired as metal fabricators, an unglamorous job that often involves making thousands of parts in a repetitive fashion. But when work slows down, Woggon and Scott use their artistic talents in the factory.

CONTINUE READING ONLINE ->

Gone are the days of waiting hours and hours for your length of pipe to warm up to the right temperature –

Miller has just released the new ProHeat 35 Induction Heating System, which works by inducing heat electromagnetically, rather than via a conductor, thus saving the operator incredible amounts of time and energy.

Simply wrap the induction coils around whatever piece of metal you’re working on, and in just a few minutes, you’re ready to go!

This picture was taken looking inside the length of pipe that was being heated up by the ProHeat 35 — you can’t see it here, but that tube was glowing red hot on the inside!

And even better, when I tried touching the coils wrapped around it?
Cold as ice! This product is simply amazing!

But perhaps the best part about this whole new system is that you don’t even have to buy it! Red-D-Arc will rent out one of their machines to you for as long as you need!

Ron Patrick’s Street-Legal Jet Powered Volkswagen Beetle

This is my street-legal jet car on full afterburner.

The car has two engines: the production gasoline engine in the front driving the front wheels and the jet engine in the back.

The idea is that you drive around legally on the gasoline engine and when you want to have some fun, you spin up the jet and get on the burner (you can start the jet while driving along on the gasoline engine).

The car was built because I wanted the wildest street-legal ride possible.

With this project, I was able to use some stuff I learned while getting my fancy engineering degree (I have a PhD in Mechanical Engineering from Stanford University) to design a street-legal jet car without the distraction of how other people have done it in the past – because no one has.

I don’t know how fast the car will go and probably never will. The car was built to thrill me, not kill me. That doesn’t stop me from the occasional blast on the highway though.

CONTINUE READING ONLINE ->

But his – well, with just a few adjustments, it’s more of a possibility than you might think.

In North Kitsap, Turning Old Cars Into New Planes

By GENE YOACHUM FOR THE KITSAP SUN

Brady McCormick has his eyes on the skies.

The machine shop owner sees an opportunity looming in building experimental aircraft power plants out of 40-year-old Corvair automobile engines.

McCormick, 42, said the recent announcement that Seattle-based Boeing Co. is opening a plant in South Carolina instead of Puget Sound “creates a vacuum’’ for aircraft manufacturing locally.

“Now’s my chance to fill that vacuum,” he said, tongue planted firmly in cheek. “I haven’t found the plans yet for a 747, but as soon as I do, they are in trouble.”

McCormick’s plans for building experimental airplanes powered by Corvair engines is no joke.

Pulled from wrecking yards and scrap heaps, engines from Chevrolet’s once-popular compact car are perfect for experimental aircraft enthusiasts to rebuild and convert into airplane engines, he said.

CONTINUE READING ONLINE ->

ArcTime™ Brand Hybrid, One Tungsten Blend For All Materials

ArcTime™ Brand Hybrid, One Tungsten Blend For All Materials

State-of-the-Art, Non-Radioactive Tungsten Electrode Formula: For all metals, compatible with all welding machines.

Fabricators from around the world are using ArcTime™ Hybrid tungsten electrodes to improve weld-quality, lower tungsten inventory costs and minimize weld defects.  What started as “cult  product” with a few specialty manufacturers of yatch towers, aerospace parts, mountain bikes and race cars has grown into our most poular tungsten electrode product.

Professional fabricators choose ArcTime™ because of its excellent ignition properties, low burn off rate and tip longevity.  In other words, this stuff lasts!

As an added bonus, ArcTime™ hybrid tungsten electrodes work well with all power sources and all metals from mild steel to titanium. The material is clearly differentiated by it’s Sky Blue™ color code.

The NEW ArcTime™ offers all that, at a price even a hobbyist or small weld shop can afford.

We are so certain that you will benefit from the new ArcTime™ Hybrid, we are offering a Unconditional Money Back Guarantee backed by our industry-leading No-Hassle Return Policy.

“You’ll notice a difference just by striking the first arc– no finer electrode exists anywhere,” says Jim Watson, president and founder of Arc-Zone.com, Inc.

ArcTime™ Hybrid Performance Tungsten Electrodes™ pass Arc-Zone.com’s 5-Point Inspection Program and are delivered complete with Arc-Zone’s popular Guide to Tungsten (pdf), and Material Safety Data Sheet (pdf) .

See What Customers Are Saying:

Amazing TUNGSTEN. I never have to switch it out when I weld something new and the arc always strikes perfectly. I am on this for the rest of my welding days!!

Date Added: 05/14/2009 by Roger Wilcox

Some of the best large tungsten I have ever used. I am a definite believer from now on. And they set me up with a Net account in a couple of minutes. A wonderful experience.

Date Added: 05/25/2009 by Duncan Moore

We started using the ArcTime after we had some major quality issues with our tungsten supply. One of the challenges of being a government entity is the material is supplied for a variety of reasons, and most times quality is not one of them! We were using the 1.5% and 2% Lanthanated material, and it varied in performance and each supplier had a box with a different label on it which did not sit well with our welding shop instructor. We tested the ArcTime material and were very pleased with the look of the material, the supporting documentation and most importantly the performance. We do maintenance welds on Aluminum ship hulls – the ArcTime hybrid tungsten out performs all other materials, and saves us a lot of headaches. Now we can focus on welding!

HT2 Hull Technician Pacific Fleet (sent via email)

Date Added: 06/25/2008 by Arc-Zone Admin

Check out what our very own Roxy Fuel has to say about ArcTime™:

Try it for yourself, then tell us what YOU think!

Customers tell us all the time that the gas saver pro kits improve their  TIG welding performance, improve weld visibility, and offer better shield gas coverage and lower gas consumption.

In other words, its worth it:

The Arc-Zone Weld Like A Pro™ Deluxe Gas Saver Kits are the Ultimate Boxes of High-Performance TIG Torch Accessory Parts — Assembled by The TIG Welding Experts at Arc-Zone.com®

Everything You Need To Optimize Your TIG Torch, and Get the Best Quality Welds — Right out of the Box!

• With a Gas Saver™ Kit you can produce high-quality welds on a consistent basis for a variety of TIG welding applications in many cases replacing bulky and expensive trail shields.
• The Pyrex glass nozzle offers excellent visibility of the weld puddle and the tungsten electrode– ideal for inside corners, inside pipe and around tubing etc.
• Gas Saver™ kits are available in tungsten electrode sizes from .040″ (1.0mm) to 1/8″ (3.2mm) and are engineered with a replaceable tungsten adapter and universal collet for low cost screen replacement.

The CK® Standard Diameter Gas Saver™ kit saves up to 40% of shield gas consumption and provides better flow patterns allowing for electrode stick-out of up to six (6) times electrode diameter. Gas Saver™ kits are lightweight, for improved operator comfort and torch control.

The CK® Large Diameter Gas Saver™ nozzle kit is used to provide an inert atmosphere for the welding of reactive metals such as titanium, molybdenum, nickel-based and aluminum based alloys as well as non-reactive metals like stainless steel. The nozzle is a whopping 1-1/8” (28.5mm) in diameter for ultimate shield gas coverage!

What Customers Say:

This kit is worth the money. You can switch out multiple sizes and reordering parts is very easy.

Date Added: 07/18/2009 by Fab Shop

Thanks for the kit gentlemen. It came exactly as described and the clear nozzle really helps. The tungsten sample pack makes really good welds. CHEERS.

Date Added: 05/05/2009 by John Crane

My torch looks exactly like the picture. This kit came with everything I needed. Thanks for the tungsten, works great.

Date Added: 05/19/2009 by Ron Doll

Get your KIT today–>