enhance weld quality

4 Tips to Enhance Weld Quality

Excellent weld quality helps to build a competitive advantage for your manufacturing business. With the right process in place, you will be able to regularly deliver durable, strong and clean welds to your customers. Read on to get our 4 simple tips to enhance weld quality.

  1. Proper Placement

  2. In-process Monitoring

  3. Use Automated Welding Machines

  4. Quality Assurance Checks

 

The Cost of Poor Weld Quality

Before we get into our tips, let’s review some of the most common welding problems:

  • Spatter
  • Porosity
  • Undercut
  • Deformation
  • Cracks
  • Poor weld penetration
  • Incorrect wire delivery

These issues are often structural in nature while also affecting the overall appearance of your part. Low weld quality will hurt your bottom line, be a strain on your work environment and negatively impact customer satisfaction. Some issues could even be a safety hazard resulting in damage, injuries to workers or worse!

 

Tip #1: Proper Preparation

The steps before the welding process takes place are some of the most critical! Learn more about tips to prepare metal before automatic welding right here. When you skip out on cleaning your metal surfaces, removing oxide layers or prepping the metals edge—you’re setting yourself up for disaster. It’s worth your time to complete all best-practice welding preparations so you can not only pass quality inspections but also get beautiful and clean welds!

 

Tip #2: In-Process Monitoring

Real time, in-process weld monitoring is a great way to stay on-top of weld quality and catch errors before they occur. Some techniques used today for process monitoring include sensors, lasers and vision-based monitoring. Seam tracking allows you to track weld position during the welding process. This results in better welds, improved path speed, decreased scrap and reduced cycle times. Check out our run-down of seam tracking and how to select the right solution for your project right here.

  

Tip #3: Automated Welding Machines

Using the proper welding equipment is the first step for ensuring high-quality welding output. Automating your process can keep welding pitfalls at bay. Up-to-date technology makes a huge difference when it comes to avoiding welding defects—automation makes welding more consistent and reliable.

Bancroft Engineering provides both standardized and customized welding solutions. From semi-automated welders to 100% robotic cells, our engineers can help you select the right system for your process. Check out more information about our welding system offerings right here!

  

Tip #4: Quality Assurance Checks

Our last tip for improving weld quality is to have strong quality control in place. A welding quality assurance inspector reviews the weld and tests it’s quality. Quality assurance checks should focus on the overall quality of the weld as well as the strength of the weld. The main benefits of having quality control in place is to catch problems, analyze them and determine the best way to fix the issue moving forward.

 

Step up Your Weld Quality

Bancroft Engineering is here to help you improve weld quality with state-of-the-art equipment. We offer both design and build services under one roof. Specializing in standalone semi-automated welding machinery and large, automated weld systems, we offer full-service welding support. Give us a call today at 262-786-1880, or email: sales@bancrofteng.com.

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custom welding system

Quality Welding Fixture

Our team understands welding.  It’s a difficult and physically demanding job. Aside from the physical complications of precision welding, complications can also result from poor placement of the parts.  Taking shortcuts with your job’s welding fixture can cause severe quality problems down the line, making your welder’s job more difficult and less accurate. To ensure your welder is performing to the best of their ability, it is imperative that they have THE RIGHT TOOL FOR THE JOB.

 

custom welding system

 

When beginning a new project, many things must be considered in the fixture design:

  • Choose your fixture material wisely
  • Orient the fixture maximize deposition rates
  • Strive for quality, durability, accuracy, and repeatability
  • Consider alternatives when designs are cost-prohibitive

 

Bancroft’s team can design a custom holding solution for your manual welding or automatic process that is both durable and cost-efficient. From designing and building multi-step robotic applications, durable tack stations, or intricate rotating jigs and fixtures, our team has the experience to “MAKE IT HAPPEN.

 

custom welding fixture

 

Anyone who’s ever struggled to get a weldment out of a poorly designed fixture will attest to the importance of fixture design.  At Bancroft Engineering, we understand the amount of detail required to design and build the simplest and most complicated weld fixtures.  A good welding fixture must have it all: quality, durability, accuracy, and repeatability.

 

Bancroft Engineering designs and builds welding fixtures for a wide range of manufacturers.  Our engineer’s 3D model every fixture design in SOLIDWORKS® for your review and approval followed by managing the complete project including fabrication, assembly, and final testing.

 

welding fixture

 

Welding Fixture

Whether its cycle time reduction, improved accuracy and precision or both; we invite you to share your unique challenges with us.  Let one of our engineers get started on a custom welding fixture for you.  We pride ourselves on face to face meetings and give personal attention to every customer. Whether you want to communicate by phone or email or visit us in person for a tour and hands-on demonstration, we look forward to working with you on your next fixturing project.

 

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