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.
Proper Placement
In-process Monitoring
Use Automated Welding Machines
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.
Steps to Prepare a Fab Shop for Automated Welding
Getting started with welding automation can be a big task, especially for first-time purchasers. In order to gain the desired results and a justifiable return on investment, it’s important to get started with the right implementation process.
Semi-automated welding machines or fully automated robotic cells can offer huge advantages for fab shops such as improvements in productivity, cost savings, time savings, higher quality parts and so much more.
Trends in Fabrication
Manufacturing trends and equipment technology are constantly evolving. With 2020 now underway, it’s important for your metal fab shop leaders to stay informed and proactive! Industries such as construction, automotive, food/beverage, aerospace and military/defense are all steadily growing markets and they all depend on metal fabrication. Here are just a few metal fab trends we are noticing:
- Use of automation & semi-automation
- New research and development technology
- Reliable and intuitive production monitoring
Take the time to prepare your fab shop for automated welding success with these simple steps.
Get the Team on Board
One of the main tips we have for preparing your fabrication shop for automation is to adapt your team to the new technology. It’s crucial to consider your existing shop workers and how their jobs may be affected by the shift to robotic automation or the use of semi-automated welding equipment. We recommend you encourage opportunities for advancement, explain potential benefits and be transparent about the company’s goals. This will ensure your team is well informed and ready for the transition.
Identify & Conduct Training
Learning the skills of automation is a huge opportunity for welding professionals. Automation uses cutting-edge technology, which allows welders to gain an entirely new perspective of the manufacturing process—and the art of welding. Welding technology has improved so much over the past decade that it’s made learning automation and robotics easier than ever. With user-friendly interfaces and digital controls, automated welding equipment is designed for ease of use. Here are a few process and training elements to consider:
- Determine which project to start automating
- Select a team of welding system operators
- Utilize training programs for equipment specific applications, software, maintenance, etc..
- Address workflow shifts & action steps
- Develop a clear quality control strategy
Selecting the Right Welding Automation Partner
A professional welding automation equipment builder will have experience with different welding applications and system configurations. The team at Bancroft Engineering has highly experienced engineers and support personnel that are here to help you from first concept, design and build of the automated machine and support through the equipment’s lifecycle.
Welding Automation Equipment Builder
Bancroft Engineering designs and builds welding equipment from standalone semi-automated machinery to large, fully automated weld systems. Located in Waukesha, WI, our team of welding engineers offer full-service welding support to help you automate and optimize your process. We’d love to help you get stared—give us a call today at 262-786-1880, or email: sales@bancrofteng.com.
Selecting the Right Seam Tracking Solution
In today’s highly competitive market, manufacturers must stay both lean and efficient. Taking advantage of the different seam tracking options available for your welding projects is one way to gain an edge.
Here at Bancroft Engineering, we understand the importance of optimizing your welding process.
Tactile Seam Tracking
Tactile seam tracking systems track the seam using a sensor with a tip that physically touches along the length of the seam about 2-3” in front of the arc. When a change in location or alignment is detected, the system responds and adjusts to the correct position. It can be used in almost any welding process. Tactile seam tracking is very versatile and works well on any material type. This option offers a great balance between cost and flexibility.
One disadvantage to tactile seam tracking is that the torch is adjusting in real time according to where the probe is touching not where the torch is welding. If the probe is 3” in front of the arc and a quick drastic change to the seam is detected the arc may actually move outside of the seam. To solve this problem the tracker can be paired with another type of control system to delay the correction in relation to the travel speed of the weld head or part.
Through Arc Seam Tracking
Through arc seam tracking is a type of 2-axis real-time tracking. The tracking occurs as the weld is being deposited and adjusts by monitoring the voltage across the arc. In order to shift along 2 axes’ with through arc tracking weaving is required. As the tip to work distance changes so does the voltage across the arc. This change in voltage is monitored and used to adjust the path of the torch, maintaining proper weld position in the joint.
Laser Vision Seam Tracking
Laser based vision tracking, also referred to as optical tracking, involves a laser beam device which hits the welding surface, reflects off and bounces back to the sensor. With this technology, the sensor then recognizes exactly where the seam is located. Laser vision seam tracking is highly reliable and great for high speed welding applications for both small and large parts.
Touch Sensing
Touch sensing, or wire touch sensing, is the physical touching of the weld wire to the welding surface to detect the joint. Most commonly used in robotic welding applications, this type of seam tracking uses low voltage through the welding wire or torch tip to search and detect the welding surface and seam. The seam needs to be detected prior to welding so the cycle time can be double or more compared to that of other methods.
Each tracking system has its positives and negatives. Work with a Bancroft weld specialist to understand which one is the best option for your process. Located in Waukesha, WI, our team of welding engineers are here to help you automate and optimize your process. Give us a call today at 262-786-1880, or email: sales@bancrofteng.com to get started.
Semi-Automatic Welding Machine –The Best Choice
Ready to optimize your manual welding process to a more efficient operation and consistently improve your end products? Updating your welding methods with a semi-automatic welding machine will take your manufacturing process to the next level—all while increasing your profit margin.
Robotic or fully automated welding is not ideal for every project—expected lifetime of the job, the cost of tooling and the flexibility required are all factors that should be considered. That being said, semi-automated welding systems are a great option because they can double the output of a skilled manual welder while still maintaining a high level of control.
What is Semi-Automatic Welding?
Semi-automatic welding is a form of manual welding that utilizes the proper equipment which automatically controls one or more of the welding conditions. The machine operator manipulates the controls of the machine to start welding and observes the process and end result for quality. This is helpful to workers as it’s much less physical demanding than manual welding.
Advantages of Semi-Automated Welding Machines
Applications that benefit most from semi-automated equipment is when the quality or function of your weld is highly critical, if repetitive welds must be made, or if the parts already have gone through added-value processes before the welding begins. Semi-automatic welding systems offers a host of advantages for a variety of applications:
- Enhances worker safety
- Maintains high-quality welding output—integrity and repeatability
- Increases overall product output
- Decreased scrap produced
- Less expensive than robotic welding
Welding Machine Types for Every Application
Bancroft Engineering specializes in robust semi-automatic welding machines—both standardized and custom solutions. No matter what type of welding projects you have, semi-automatic machines give you repeatability with the touch of a button!
Weld Lathes: Our line of weld lathes are built for speed and quality output. We also offer lathe machines that include built-in secondary operations such as drilling, milling and cutting to maximize your production line even further.
Rotary Welding Equipment: Economical, compact and robust, our line of Rotary Welda-Round machines are a great option for welding operations dealing with a variety of parts and material types.
Seam Welding Machines: Seam welding is common in many industries after forming materials into cylinders or tubes. Semi-automated seam welders are able to create uniform consistency across the entire length of the material.
Linear Welders: Linear welding systems are designed to automate straight welding applications. These machines are commonly used for both small and large-scale projects.
Semi-Automatic Welding Systems Built in Waukesha, WI
Our team offers welding equipment from simple rotary and linear drive machines to multi-axis, servo systems with robotic integration. Interested in learning more about Bancroft Engineering and what we can do for your welding process? Get in touch with us to discuss your project!
Section 179 Expensing for Welding Machines in 2019
With the new year right around the corner, it’s a great time to plan for tax savings before it’s too late. Purchase automated welding machines from Bancroft Engineering to not only improve your manufacturing process but also to save your business money during tax time.
How Does Section 179 Expensing Work for Welding Equipment Purchases?
Section 179 of the United States Internal Revenue Code (26 U.S.C. § 179) is now available which allows you to write-off up to $1,000,000 of a qualifying equipment purchase for 2019.
In previous years, when businesses purchased welding equipment, they would write it off little by little through depreciation. For example, if your business spends $75,000 on a piece of machinery, you might write off $15,000 per year for five years.
Now, with Section 179, a business can write-off the entire purchase price of qualifying equipment for the current tax year. As in our previous example, if your manufacturing business spends $75,000 on a piece of automated welding machinery, you can write off all $75,000 in the same tax year using Section 179. This makes a big difference for small and medium-sized businesses as it allows you to accelerate your tax savings!
How to Qualify for Section 179
Section 179 is an attractive tax deduction for manufacturing businesses—it’s also easy to understand and utilize. Most new and used tangible business equipment qualifies as long as it meets the following criteria:
- Equipment must be installed and ready for service in the same tax year
- More than 50% of the use of the equipment must be used for the business
Real Example of Section 179 Expensing
- Cost of equipment after Bancroft Engineering Discounts: $175,000.00
- Section 179 Deduction: $175,000.00
- Total First Year Deduction: $175,000.00
- 35% Saving on Equipment Purchase: $61,250.00
- Lowered Cost of Equipment After Tax Savings: $113,750.00
Utilize Section 179 with Your Next Automated Welding Machine Purchase
There has never been a better time to purchase welding equipment and take advantage of major savings!
Bancroft Engineering designs and builds welding equipment such as standardized and custom welding machines and much more out of Waukesha, WI—specializing in stand-alone equipment to fully robotic automated systems. Need help automated your welding process or have a special welding application? Give us a call at 262-786-1880, or email: sales@bancrofteng.com to get started.
Precision Weld Lathe Machine Uses
Automated weld lathe machines are designed and built for both small and large welding applications. Lathe welders are commonly used to weld seams or to join multiple components together. Here at Bancroft Engineering, we take pride in building the best precision weld lathes for manufacturers looking to automate—or just improve their overall welding processes!
About Weld Lathe Equipment
Precision weld lathe machines provide a versatile way to rotary weld production parts. Whether you’re in need of vertical, horizontal or inclined drive orientations, a weld lathe can be aligned to optimize and improve your production line. Check out Bancroft’s line of premium weld lathe machines below:
Model 605: The fully functional 605 model welder is a budget friendly alternative for circumferential welding cells. This system is designed to achieve a maximum welding rates as well as high-quality output with minimal labor costs.
- Precision machine bed
- Digital controls
- 500 lb load capacity
- Auto cycle operation
- 400 lb camping force at 80 PSIG
Model 1210: This welding lathe is powerful yet designed with simple setups in mind. It offers more consistency and repeatability than less controlled welding methods.
- Precision machine bed
- Digital controls
- 1000 lb capacity
- Auto cycle operation
- 650 lb clamping force at 80 PSIG
Synchronized Drive Lathe: These automated lathe machines are used to join two or more components that have radial orientation. With the focus on speed and quality, Bancroft’s synchronized drive weld lathes are versatile and production ready. Check out more details here.
Top Industries
Whether you have large parts or small, precision components, our wide range of lathe configurations can be used to meet your needs. Bancroft Engineering builds standard and customized weld lathe machines for a wide-range of industries and applications including:
- Automotive components (exhaust, wheels, suspension, torque converters, etc.)
- Hydraulic cylinders
- Pressure vessels
- Tanks
- Construction applications
- Military components
- Job shops & metal fabricators
Customizable & Flexible
Looking for something specific? Weld lathes can be customized to fit any circumferential and linear TIG, MIG or plasma welding requirement. Leave it to our team of highly skilled engineers and technicians to build a custom weld lathe machine that exceeds your expectations.
Precision Weld Lathe Manufacturer
We strive to design and build the right equipment for your job! From standalone solutions to complex fully-automated systems, our work is always backed up with quality installation, field service and support.
Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems. Ready to learn more about adding a precision weld lathe machine to your shop floor? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.
Tips to Prepare Metal Before Automatic Welding
Understanding the importance of clean metal before you begin any automatic welding, semi-automatic welding or manual process is key to a strong end result. Skipping the metal preparation step is one of the most overlooked tasks in the welding process, but it shouldn’t be! You run the risk of failing quality inspections or end up with ugly—or even weak welds.
Material preparation will vary depending on what type of tools you have such as automatic welding equipment, rotary welding systems, TIG welding cells or if you are welding manually. It will also depend on what type of metals you are using. Read on to get our general best-practice tips on how to prepare metal before welding.
Keep it Clean
Beginning with clean, debris-free material is the best way to ensure positive outcomes. Before using an automated welding system, remove any paint, oils, grease or rust. Here are a few common tools used to clean metal:
- Sandpaper
- Abrasive blasting
- Stainless steel brushes
- Solvents such as acetone or other alkaline cleaners
Avoid creating any deep scratches when cleaning your material as removing too much material from the metal can result in poor weld quality and costly rework. Always organize your cleaning utensils and keep ferrous and nonferrous tools separate. Cross-contamination can occur when the wrong cleaning tool is used.
Removing Oxide Layers
If you’re welding with aluminum, it can add an extra element of difficulty due to the nature of the metal. Aluminum has a greater risk to develop weld problems— such as lack of penetration—due to the tough oxide layer. Other metal materials may also have a coating on them to avoid rust during shipping. Oxidation can from quickly, so it’s best to clean small areas at a time right before the automatic welding process begins.
Joint Preparation
Preparing the metal’s edge is a critical step that allows the filler metal and part edge to fuse together without melting. Depending on your parts, one of these basic weld joints should be used:
- Butt joint: parts are on the same plane and they are joined at their edges.
- Corner joint: parts form a right angle and are joined at the corner of the angle.
- Tee joint: one joint is at a right angle, while the other resembled the letter “T.”
- Lap joint: formed with two overlapping parts.
- Edge joint: joints are parallel with each other and are joined at the seam.
Proper Storage
A major challenge is preventing indirect material contamination from dust or other airborne particles floating through your shop floor. While you can’t stop dust and dirt completely, here are a few material storage tips to keep in mind:
- Store in a dry location
- Ensure minimum temperature fluctuation
- Cover materials with plastic or thin sheets of cardboard
Automatic Welding Systems
No matter what type of welding you are performing, it’s important to take the time to prepare your material before you get started. It’s worth the extra effort to get a strong weld that also looks perfect!
Bancroft Engineering designs and builds welding equipment such as rotary welders, weld lathes, seam welders and much more out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems. Need help automated your welding process? Give us a call at 262-786-1880, or email: sales@bancrofteng.com to get started.
NEW Weld Lathe Machine + Secondary Operation Add-On
We are proud to be offering NEW weld lathe equipment that also includes added-value operations—all in one piece of machinery. Our standard 605 and 1210 model circumferential welding systems have always been designed with flexibly in mind. Now, we are offering the availability of even more options to customize a solution to fit all of your welding, machining and other fabrication needs.
We believe that your next piece of automated welding equipment should perform above average! These brand-new lathe machines with added machining applications offer high repeatability, extreme consistency and minimal run-out.
Value-Added Operations
Along with our standard welding machine product lines, Bancroft Engineering also provides customized solutions to fit the demands of any project. We now offer the possibility of adding secondary operations. Have metal parts that need to be welded and drilled? Now, this can be done all in one machine—saving time and labor while optimizing your production line.
Machining Secondary Operation Add-Ons:
- Drilling
- Milling
- Cutting
- Custom machining tasks
Standard Machine Features
Bancroft’s weld lathe family is one of the most versatile ways to rotary weld production parts. Our standard product line of weld lathe machines come with a plethora of features and specifications:
- Accurate machine bed
- Modern digital control System
- DC rotary drive
- 500-1000 lb. load capacity
- Automated cycle operations
- Adjustable operator console
- 400-650 lb. clamping force
- 4”x4” cross-side torch adjustability
- Standard air-cooled torch
- Much more…
- See All Standard Features
Weld Lathe Custom Configurations
- Multiple weld torch & frame configurations
- Programmable torch positioning
- Torch Weaving
- Programmable multi-pass welding
- Machine enclosure and flash shields
- TIG, plasma or submerged arc applications
- Tooling and factory runoff
- Much more…
- See all Custom Options
Weld Lathe Machines + Secondary Operations Combined
We are excited to expand the weld lathe family to include value-added machining operations. Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems.
Ready to take the next step? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.
Circle Welders – Automated Welding & Machines to Match
Dedicated welding equipment, such as automated circle welders or rotary welding equipment, are great additions to any welding/fabrication operation. Our line of premier Welda-Round machines offer options for manufacturing projects of almost any alloy or welding method. Automated circle welding systems are designed to be economical and repeatable.
Some major benefits of circle welders are:
- Higher levels of production than manual process and even robotic systems
- Lower installation costs than other automation cells
- Highly repeatable welding output
- Easy to set up, operate and maintain
- Takes up minimal shop floor space
Let’s get into our rotary welder offerings, some of their standard features and how you can customize each piece to fit your welding projects.
MODEL 300 – MIG Circle Welder
This is the most popular circular welding system in the welding industry today! With a 75-pound head clamping force, this machine is heavy duty yet compact. Each 300 Model Welda-Round has the latest automated welding digital controls and technology for easy setup and operation.
- DC rotation drive
- Adjustable operation console
- CNC machined tooling arms
- MORE…
MODEL 350 – Rotary TIG Circle Welder
The Model 350 is a high capacity rotary welder that is capable of a single revolution weld cycle in a matter of seconds. It has high-frequency protection as well as drive delays and overlap controls. This robust TIG welding machine has a 360-degree rotation torch, perfect for any demanding job.
- Adjustable 8-inch vertical stroke
- Standard air-cooled torch
- 300 amp and 70% duty cycle
- MORE…
MODEL 500 – Port Welder
The larger and more robust Model 500 port welder offers extreme welding rigidity and accuracy. The duel torch system and a 100-pound clamping force are all situated on a heavy-duty frame. It’s the perfect machine for larger weldments and all other circumferential welding projects.
- 500 Amp duty cycle
- 50-550 IPM integral wire drive
- .7 to 14 RPM rotation speed
- MORE…
MODEL 550A – Aluminum Rotary Welder
Ultimate wire feeding capability for aluminum spud welding. When welding aluminum special care must be taken to properly feed soft aluminum wire. The 550A was developed using a slip ring assembly allowing the wire spool to rotate with the torch. This eliminates whip or twisting of the aluminum wire to prevent weld defects.
- Flexible configurations for headers and other pressure vessels
- Can be configured for all Arc Welding Processes
MODEL 600 – Fitting Welder
For unbeatable speed and quality, the Model 600 fitting welder is exactly what every modern welding shop needs. The arc time on this machine is drastically reduced as the rotating torches can travel 180-degrees and has an adjustable overlap. With a hefty 750-pound head clamping force, the model 600 Welda-Round is an all-star piece of welding equipment.
- Floor mounted operator console
- Fabricated tooling arm
- Wire drives
- MORE…
Rotary Welder & Circle Welder Machines Made in Wisconsin USA
All of our standard circle welders can be fully customized for your unique requirements. Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems.
Ready to learn more about a customized welding system for your company? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.
Trade-In Trade-Up Welding Machine Program
Is your Bancroft Welda-round starting to show signs of aging? Do you think it might be time to replace your old Bancroft welding machine and trade-up to a newer, more efficient model that can truly fit your needs?
We recently had a customer approach us with this exact situation. We started our normal process of quoting them a new machine and/or to rebuild their existing equipment. They responded with, “I like the rebuild idea, but we cannot afford the downtime.”
Bancroft Rotary Welding Machines
This got our sales team thinking! “We either need to stock a refurbished 300 Welda-round so we can send it to our customer and trade them for their current machine. OR, can we send a new machine at a discount and take their old machine in on trade?”
The answer? Our new Trade-In Trade-Up Program! Trade-in your old Welda-round and your new rotary welding machine will come with all the same options as your current machine plus give you the capability to add on more features to suit your needs.
We hope our new Trade-In Trade-Up offering will significantly help our existing customers. Here are a few big perks for utilizing this new program:
- Use the latest and greatest in automated welding technology
- Ensures you’ll get a great price for your former or out-dated machine
- Eliminates the inconvenience of downtime
- Removes the hassle of waiting for the older machine to be sold, uninstalled and moved out of the way
Get Started with the Trade-In Trade-Up Welding Machine Program
To trade-in your old welding machine, simply send us a picture of it. Within 48 hours you will receive a quote that will include your trade savings. We guarantee a minimum of $5,000 in savings regardless of your machine’s condition!
Included in this program, Bancroft will offer FREE shipping of your old equipment back to our plant in Waukesha, WI.
For complete details, call: 262-786-1880 or email us at sales@bancrofteng.com.