Make your own 180 Amp TIG Welder...

Really fascinating link I'm throwing at you today involves Dave Barret's quest to make his own TIG welder from scratch. This project is built around TTL and CMOS logic to keep it simple, repeatable and easy to trouble shoot.

Here's his list of features:

1/ AC-DC welding variable via two thumbwheel switches from 1% (all Negative) right through full range of AC to 99% (all Positive).
AC frequencies available from 15 to 400 Hz
2/ Pulse Frequencies fully variable from .3 to 10 Hz This does away with having to pulse the foot peddle on thin materials.
3/ Variable control for Maximum Welding Current available to the Foot peddle control.
4/ Variable Start Current (period of higher current available (higher than max set) for short time heating of thick materials)
5/ Variable Start time for above.
6/ Variable End Current (Crater).
7/ Variable End Current time.
8/ Variable Gas Start time.
9/ Variable Gas End time (Dwell).
10/ HF Arc Start.
11/ Opto Interupter / Potentiometer foot peddle current control.

The page is packed with photos, schematics, even printable PDF's. It's a great piece of work.

2006 FabTech welding show moves to Atlanta

Reflecting a move of manufacturing and fabrication to the South, mondo welding show FabTech is moving to Atlanta this year.

The FABTECH International & AWS Welding Show is the largest event in North America dedicated to showcasing a full spectrum of metal forming, fabricating, tube & pipe, and welding equipment and technology. In 2006, the event is heading to a new city - Atlanta, Georgia! Thousands of buyers and sellers from around the world will gather at the Georgia World Congress Center to exchange products and services, form new business relationships, problem-solve, and share best practices. Be a part of this exciting manufacturing tradition - make plans now to exhibit or attend the 2006 FABTECH International & AWS Welding Show.

On the Manufacturing Talk website, show manager Mark Hoper said that, "We will continue to produce our show in Chicago in the odd-numbered years, but we look forward to enjoying the warm autumn weather so characteristic of Atlanta in October."

More than 500 exhibitors have already signed up as of March 1, 2006 and another 100 are expected to join this group by October.

Sounds like the place to be this fall for welders.

Airgas expanding in Wisconsin; buying Airtec

According to MSN, Airgas, which has about 600 distributors nationwide, is buying Airtec. Inc. Airtec is based in the midwest, where Airgas is trying to expand its business base. The consolidation in the gas business continues...

Caps for a bit of personal style

Really, any old thing will do, but there are some guys out there who want a cap, a helmet, and everything else fashionable, even if there is slag flying.

The Louisiana Advocate calls it a "fashion statement for men." Once hand sewn by wives, girlfriends and mothers from mattress ticking, the caps are now worn by welders worldwide. Worn with the floppy bill in front, the cap protects the forehead. Worn sideways, with the bill down, the welder’s ear closest to the work is protected. Some Comeaux caps are reversible. That lets a welder change style between shop and truck. The extra layers of cloth also provide more cushioning between welder’s head and helmet. So the things do have some function, if you just gotta have a flag, or a dots or fruit or whatever on your head while you weld...

MG welding offers productivity gain analysis online tool

MG Welding has a nifty welding productivity calculator you can play with over on their site.

Just enter your data and click "calculate" to estimate the gain in plate cutting productivity (inches cut per shift hour) when using MG Systems' technology. The application used is 1/2" thick mild steel plate (8' x 20') with 160 parts and 320 pierces, cutting 10 shifts per week.

The site warns that actual results may vary based on your application. It's more of a calculate for ballpark range, in my opinion, but very worthwhile for theorizing. I did a basic calculation and it spat out a 72% productivity gain, given my numbers.

Plate Processing Productivity Gain Estimator

Productivity Gain using MG technology:
72%

Based on the following:
		Current Method		MG Advanced Technology
Process Selection (ref only):		Plasma		Plasma
Cutting Process Speed (IPM):		140		160
Number of torches:		1		1
Rapid Traverse Speed:		500		1000
Torch Lifter Speed:		180		880
In-Cycle Portion of Shift Time (%):		40		45
Cutting Support Table Cleaning:		4 hours / week		5 minutes / Day