Welder Training Tips To Help Improve Productivity

Estimated reading time: 6 minutes

Improving productivity in semi-automatic operations isn’t simply about welding faster and working harder. Instead, there are ways to create consistency in the process and support quality so that companies can avoid downtime that adversely affects throughput. 

When training new welders, it’s important to provide a solid foundation of knowledge to achieve the best results. Taking the time to establish and expand welders’ skill sets shows welders companies are invested in them, and as welders gain more experience, they become more confident. The aim is to empower them and provide all the information necessary to be productive. 

To instill good habits from the start, consider some key training tips.

Put safety first

A safe welder is a productive welder. By training new welders to follow welding safety protocols, there is less risk of lost productivity due to injury. Wearing the appropriate personal protective equipment (PPE) is important. This includes a properly fitted helmet, safety glasses, flame-resistant jacket or sleeves, welding gloves and steel-toed, rubber-soled boots. If the process is prone to higher levels of fume generation, correct use of a respirator is necessary. Train welders to read and follow all equipment labels and their owner’s manual carefully before operating welding equipment. Training also includes checking the power source ground, securing workpieces in the best possible manner and keeping their heads out of the weld plume when welding. 

Establish consistent weld prep

Following best practices for weld prep supports high weld quality, reduces rework and scrap, and improves productivity. As part of new welder training, welders should understand their power source settings, type and levels of the shielding gas being used, and how to clean the base material. Checking that all welding consumable connections are tight can minimize electrical resistance that could lead to burnbacks (the formation of a weld in the contact tip) and downtime for tip changeover.  

Install welding consumables correctly

Downtime to address liner issues is common in semi-automatic welding operations and is typically caused by incorrect installation. This can lead to bird-nesting (a tangle of wire in the drive rolls), poor wire feeding, an erratic arc, wire chatter, burnbacks and more. Always use a liner gauge when trimming a liner; or consider a consumable system like AccuLock™ S, which provides error-proof liner installation without measuring. The liner locks and is aligned to the power pin and the contact tip to ensure proper wire feeding. New welders should also learn to install and tighten contact tips according to the consumable manufacturer’s recommendation. 

Focus on comfort

Training welders to pay attention to their posture and the angle they hold their MIG welding gun can help reduce fatigue and the risk of welding-related musculoskeletal disorders that lead to lost productivity. Whenever possible, welders should position themselves so they are welding the workpiece in the range between their waist and shoulders. This may require a work stool or adjustable chair. Welders should also keep their hands and welding gun at or slightly below elbow height. Gaining good visibility to the weld joint can encourage proper posture. 

Follow welding procedures

Welding procedure specifications (WPS) are a means to create consistency in the welding operation by taking the guesswork out of the process. This document outlines welding parameters, filler metal type and diameter, wire feed speed (WFS), weld pass sequence and more. Training new welders to follow the details in a WPS can help ensure that they produce quality welds and remain productive. 

Use the right equipment

New welders should be trained to use the best equipment and tools for the job — and ones that best suit them. A MIG welding gun that fits the welder’s hand comfortably will help maximize their time when welding. Using a hammer for repositioning a part, as opposed to the MIG gun itself, can prevent damage to the gun that leads to downtime for repairs or replacement. 

Likewise, having the correct wrench for installing gas diffusers or welpers for tightening contact tips helps ensure snug connections and lessens the opportunity for issues. Using the wrong tools or not tightening parts properly leads to loose connections that cause electrical resistance. This, in turn, increases heat and wears out the equipment prematurely. 

Employ proper techniques

Welding techniques vary according to the process, the welding position and the thickness of the base material. For example, when MIG welding with solid or metal-cored wire, welders need to learn to use a push technique, while a flux-cored process requires a drag technique. Train welders on the proper gun angles for flat, horizontal and out-of-position welding applications so they are able to fill the joint with the appropriate amount of weld metal and avoid issues like lack of fusion.

Recognize signs of trouble

Training new welders to quickly identify issues in the welding process can minimize downtime for troubleshooting. They should be given the guidance to identify the causes of common problems like porosity, burnbacks, poor deposition and more, along with their solutions. Welders should also be able to recognize signs that equipment needs to be repaired or replaced — for example, a welding contact tip that is keyholing (wearing at the bore unevenly) or a gun that has nicks in the power cable. Companies can provide troubleshooting cards with quick checklists to keep in the weld cell as reminders. 

Keep communication open

Clearly communicating expectations to new welders and having supervisors who are responsive to questions are vital parts of training. It is about both learning and listening. As training continues and welders grow their skill sets, it’s important to establish two-way feedback. This way everyone can find common ground on what best practices could be. In some cases, new welders may identify a way to improve the operation based on experience they have from another job. 

Successful new welder training

When companies commit to providing thorough new welder training, the aim is to establish skills that lead to consistency in quality and reduce downtime. The more they can avoid secondary work or additional processes, the better productivity will be. Plus, supporting the comfort and safety of welders can help make sure they perform their best every day, build confidence and help retain them as employees. 

5 Tips for Improving Weld Quality

Estimated reading time: 7 minutes

Establishing consistent levels of weld quality is important for attaining production goals and a better bottom line in semi-automatic welding operations. However, there are many factors that can negatively impact those efforts, including a lack of skilled labor, inadequate or aging equipment or using the wrong welding consumables. 

To avoid costly rework associated with poor weld quality, it’s critical to implement proper welder training. Evaluating the welding operation on a regular basis for issues can also help, along with following these key tips. 

No. 1: Size contact tips correctly

Welding contact tips are available in a range of diameters — typically 0.023 to 1/8 inches — to accommodate different welding wire sizes. The wire packaging, in part, determines what size contact tip is appropriate to support good weld quality. 

Welding wires in larger drums — 500 pounds or more — have a larger cast and are flatter so there is less degree of arc. This means there is less opportunity for the wire to make consistent contact when feeding down the bore of the contact tip, resulting in an erratic arc and weld quality issues. To avoid problems when using copper and chrome zirconium welding contact tips (with Bernard and Tregaskiss consumables), undersize them for the diameter of wire. For example, match an 0.045-inch wire to a 0.039-inch contact tip. For other manufacturers’ contact tips, request recommendations. 

Copper and chrome zirconium contact tips can be matched size for size with wire on spools or in drums less than 500 pounds since the wire has a tighter cast. 

For AccuLock™ HDP contact tips, the wire and tip size can be matched regardless of the welding wire drum or spool size. 

No. 2: Size and change over liners properly

As with contact tips, welding liners are available in various diameters and ranges, from 0.035 to 0.045 inch or from 0.045 to 1/16 inch. To avoid issues like burnback (the fusing of a weld in a contact tip), poor wire feeding and an erratic arc that can be detrimental to weld quality, match the diameter of welding wire to that of the liner. This supports the wire as it feeds through the liner. 

It’s equally important to trim the liner properly. A liner that is too short can create wire chatter, an erratic arc and bird-nesting (a tangle of wire in the drive rolls). If the liner is too long, it can cause the wire to weave. Both situations can cause poor welds and, potentially, rework. 

Always use the gauge provided by the manufacturer to ensure that the liner is trimmed correctly. The AccuLock S consumable system is also a good option, as it provides error-proof liner replacement. The liner loads through the neck at the front of the gun and is locked and trimmed flush with the power pin at the back of the gun, which eliminates the need to measure. 

No. 3: Keep electrical resistance low

Electrical resistance — or interference with the flow of electricity in a semi-automatic MIG gun’s circuit — generates heat and can impede weld quality by negatively impacting the gun’s components. There are several causes that can be rectified to prevent issues such as inconsistent weld appearance or an erratic arc. 

Through ongoing use, connections begin to wear and loosen, leading to electrical resistance. Address this problem by tightening connections between the gas diffuser, gun neck and handle, as well as the connections from the power cable to the power pin and wire feeder. 

Power cable wear that results in hotspots can also lead to electrical resistance. This wear may not always be visible, so as a course of troubleshooting, operators should consider this problem as a cause of poor weld quality. Replace the cable as necessary to prevent issues. Likewise, increased electrical resistance can occur in the gun handle, since it is an area of high use and bending. Look for signs of wear and replace as needed. 

No. 4: Be mindful of cleanliness

There are various aspects of cleaning and weld prep that can help support good weld quality. Always follow proper procedures for cleaning the base material to prevent defects like porosity that can be caused by welding through dirt, oil and debris.  

It’s also important to be proactive about cleaning consumables. For example, weld spatter buildup in the nozzle or in the ports in the gas diffuser can hinder shielding gas coverage, which also leads to porosity. Clean or replace these consumables when excessive spatter is evident. Operators can also apply anti-spatter compound to the consumables by dipping the front inch and a half of the nozzle into the liquid. Use the anti-spatter compound sparingly to avoid damaging the nozzle insulator. 

Storing consumables in a clean area minimizes the opportunity for dust, oil or other contaminants to adhere to the surface of the welding contact tip, nozzle and diffuser and adversely affect weld quality. A covered container with compartments for each welding consumable is a good option to protect them. 

Also consider how to handle the welding liner during changeover. Be careful not to drag the liner on the floor while feeding it into the gun, since doing so can cause debris to collect on it and be pulled into the gun. 

No. 5: Plan for inspection and maintenance

Preventative maintenance and ongoing care of the MIG gun and consumables can go far in supporting high weld quality. Set a schedule to inspect, maintain and repair the components.

Although often overlooked during regular inspections, the O-rings found throughout the gun are important to assess. If they start to degrade or break, they can cause shielding gas leaks that lead to porosity and potentially extra costs for shielding gas if the operator increases gas flow to compensate for the leak. Check O-rings on the power pin, gas diffuser and liner during routine preventive maintenance and replace these components as needed. 

Look for damage to the power cable, such as nicks or tears that can impede gas flow. Visually inspect the gun handle for cracks or missing screws and the trigger for sticking or malfunction. Repair or replace as necessary. 

Last, inspect the welding contact tip for keyholing (an oblong wear of the bore); this can cause drifting wire and arc start failures that affect weld quality. 

Long-term results

Improving weld quality is a matter of ongoing evaluation. Supervisors and managers overseeing semi-automatic welding operations should regularly consult with welding operators to make sure they are following best practices. Ongoing training and quickly troubleshooting issues can also support good weld quality and prevent costly downtime and rework. 

Employee Retention: Best Practices for Keeping Welders Engaged

Estimated reading time: 4 minutes

The welding industry, like many others, is challenged by a labor shortage — and one that is growing. By 2023, the American Welding Society (AWS) anticipates the welder shortage to reach approximately 375,000, as an increasing number of experienced welders reach retirement age and leave the field.[1] With those statistics in mind, it’s more important than ever for companies to take steps to retain the welders they have. 

Employee retention is critical for several reasons. It helps support quality and productivity initiatives, which in turn makes it easier to meet customer demands. It also prevents overworking welders — an issue that can lead to low morale and a poor company culture. In addition, retaining welders helps maintain the bottom line. Turnover can cost companies significantly in terms of recruiting and retraining new welders, as well as for downtime in production due to lack of a full workforce. [2]

Fortunately, there are some best practices that can help companies create a positive environment and keep welders interested in the job. 

Provide proper welder training

Empowering welders is important to instill a sense of interest and pride in the job —and that process should start from the very beginning. It’s reported that strong onboarding and training can help companies retain 82% of new hires. [3]

With proper training, welders can feel confident in their ability to do the job and help train new welders. Start with establishing good welding habits and creating a familiarity with the welding process. This includes training new welders on how to set up their power source accurately and safely and on what welding parameters to use. Equally important is providing guidance on the best technique for the process and application to minimize weld defects. Establishing a comfort level with following welding procedures is also a valuable part of welder training. [4]

For more experienced welders, offering more advanced training opportunities can help keep them engaged. This could include training to weld on more complicated applications or complex parts, robotic welding programming and more. 

Create a clean, safe environment

Along with providing appropriate personal protective equipment (PPE), such as helmets, gloves, safety glasses and jackets, it is also important that the environment is safe. That means ensuring the welding cell and surrounding areas are free of clutter and any tripping hazards. It also entails proper ventilation. Companies can achieve that by removing weld fume at the source with a fume extraction gun, or with a mobile, wall-mounted system or a centralized fume extraction system. A clean, safe welding environment is more appealing for welders to work in — and it can provide an edge over competitive companies when it comes to employee retention. Additionally, be certain to train employees on all company safety protocols and welding equipment manufacturer’s safety precautions. Doing so can help create a culture of safety in which everyone is contributing. [5]

Offer easy-to-use welding equipment

Complicated equipment can be difficult to use, especially for inexperienced welders, leading to frustration about errors and downtime. This holds true not only for power sources, but also MIG guns and consumables: contact tips, nozzles, gas diffusers and liners. Liners, in particular, can be troublesome to install since it’s easy to trim them too long or too short, the latter of which happens more often. When the liner is too short, it can cause burnbacks, an erratic arc and poor wire feeding. Look for a consumable system that offers error-proof liner replacement for easier installation. This leaves welders more time to hone their welding skills while spending less time on troubleshooting. In automated welding operations, it is important to have equipment that is easy and intuitive to maintain and program after the proper training. This includes teach pendants with easy-to-use controls for inputting new parameters and requirements for the application. 

Provide growth and advancement opportunities

Offering welders a chance to advance and learn new skills can be a good way to retain those who are interested in those opportunities. Growth can take many forms, whether it’s stepping into a new role or shouldering additional responsibilities within a current position. Certifications are another avenue for growth. The American Welding Society (AWS) offers its AWS Certified Welder performance-based program so welders can expand their knowledge and technique — from plate to pipe welding with a variety of processes. There are additional programs that support advancement, including one for a certified welding supervisor. [6] 

Along with these best practices, keeping open lines of communication with welders is key — as it is in any work environment. Staying involved and creating a sense of community in which everyone is contributing to the well-being of the company can go a long way in keeping welders interested and engaged. 

Creating a Smooth Wire Feeding Path for MIG Welding

In MIG welding applications, having a smooth wire feeding path is critical. The welding wire must be able to feed easily from the spool on the feeder through the power pin, liner and gun and up to the contact tip to establish the arc. This allows the welding operator to maintain consistent levels of productivity and achieve good weld quality, while also minimizing costly downtime for troubleshooting and potential rework. 

However, there are several issues that can disrupt wire feeding. These can cause a host of problems, including an erratic arc, burnbacks (the formation of a weld in or on the contact tip) and birdnesting (a tangle of wire in the drive rolls). For new welding operators who may not be as familiar with the MIG welding process, these problems can be especially frustrating. Fortunately, there are steps to easily prevent problems and create a reliable wire feeding path. 

Welding liner length has a big impact on how well the wire will feed through the entire path. Too long of a liner can result in kinking and poor wire feeding, whereas a liner that is too short won’t provide enough support to the wire as it passes through. This can ultimately lead to micro-arcing within the contact tip that causes burnbacks or premature consumable failure. It can also be the cause of an erratic arc and birdnesting.

Trim the liner correctly and use the right system

Unfortunately, welding liner trimming issues are common, particularly among less experienced welding operators. To take the guesswork out of trimming a welding gun liner correctly — and achieve a flawless wire-feeding path — consider a system that eliminates the need for measuring the liner for replacement. This system locks the liner in place at the back of the gun, allowing the welding operator to trim it flush with the power pin. The other end of the liner locks at the front of the gun at the contact tip; it is concentrically aligned between the two points, so the liner won’t extend or contract during routine movements. 

When using a conventional liner, avoid twisting the gun when trimming the liner and use a liner trim gauge when provided. Liners with an interior profile that imparts less friction on the welding wire as it goes through the liner are a good choice for achieving efficient wire feeding. These have a special coating on them and are coiled out of a larger profile material, which makes the liner stronger and offers smooth feeding. 

Use the right contact tip and install correctly

Matching the welding contact tip size to the diameter of wire is another way to maintain a clear wire feeding path. For example, an 0.035-inch wire should be matched to the same diameter contact tip. In some cases, it may be desirable to decrease the contact tip by one size to gain better wire feeding and arc control. Ask a trusted welding consumables manufacturer or welding distributor for recommendations.

Look for wear in the form of keyholing (when the contact tip bore becomes worn and oblong) since this can cause a burnback that prevents the wire from feeding. 

Be sure to install the contact tip correctly, tightening it past finger tight to avoid tip overheating, which can hinder wire feeding. Consult the operations manual from the welding contact tip manufacturer for the recommended torque specification. 

Choose the right drive rolls and set tension properly

Drive rolls play a significant role in ensuring a MIG welding gun has a smooth wire feeding path. 

The size of the drive roll should match the size of the wire being used and the style depends on the wire type. When welding with solid wire, a V-groove drive roll supports good feeding. Flux-cored wires — both gas- and self-shielded — and metal-cored wires work well with V-knurled drive rolls. For aluminum welding, use U-groove drive rolls; aluminum wires are very soft, so this style won’t crush or mar them. 

To set the drive roll tension, turn the wire feeder knob to one half turn past slippage. Pull the trigger on the MIG gun, feeding the wire into a gloved hand and slowly curling it. The wire should be able to feed without slipping. 

Understand the impact of welding wire on feedability

The quality of welding wire and the type of packaging it is in both affect wire feeding. High-quality wire tends to have a more consistent diameter than low-quality ones, making it easier to feed through the entire system. It also has a consistent cast (the diameter when a length of wire is cut off the spool and placed on a flat surface) and helix (the distance the wire rises from the flat surface), which add to the wire’s feedability. While higher-quality wire may cost more upfront, it can help reduce long-term costs by minimizing the risk of feeding issues. 

Wire from large drums typically have a large cast when dispensed from the packaging, so they tend to feed straighter than wires from a spool. If the welding operation’s volume can support a larger drum, this may be a consideration for both wire feeding purposes and for reducing downtime for changeover. 

Making the investment

In addition to following best practices to establish a clear wire feeding path — and knowing how to quickly troubleshoot problems — having reliable equipment is important. The upfront investment for a high-quality wire feeder and durable welding consumables can pay off in the long term by reducing issues and the costs associated with wire feeding problems. Less downtime means more focus on producing parts and getting them out to customers.