ABICOR BINZEL at FABTECH 2016

This November, the annual FABTECH Expo is being held in Las Vegas, Nevada.  Taking place at the Las Vegas Convention Center from November 16-18, the expo is the largest metal forming, fabricating, welding and finishing trade show in North America.  The event this year is expected to have over 27,000 attendees and over 1,200 exhibiting companies including ABICOR BINZEL.  With a mission to bring together the metal forming, fabricating, welding, and finishing industries, and provide a forum for displays of the latest technologies and innovations, FABTECH is the can’t miss show for anyone in welding and manufacturing.

Fabtech

This year, we will be exhibiting at Booth N4704 where our product specialists and trained sales and key accounts personnel will be demonstrating the uses and capabilities of our newest products.  As a leading maker of handheld and robotic MIG and TIG torches, our products are designed specifically to meet your manufacturing needs, and your welder’s performance standards.

Here is some more information on the products we will have on display and holding demonstrations of:

  • ABIMIG SpinArc: One of our newest product offerings, the SpinArc is designed to accelerate your production operation.  Using centrifugal force and a rotating wire to produce molten droplets of metal, this unique product is proven to drastically reduce weld time. Durable and low-maintenance due to a gearless torch motion, the SpinArc plugs into any wire feeder and welding power source.  Advantages include higher travel speeds, and all position welding capabilities in a spray-like mode.  The SpinArc solves the common pain points in welding, cladding & metal fabrication, while saving you weld cost per foot of vertical down weld, and square butt joint.
  • ABIMIG AT: This extension of the ABIMIG family has the same lightweight, heavy ABIMIG ATduty welding capability of the ABIMIG WT model. Available up to 400 amps, this air cooled version provides the best handheld welding experience in the industry when used with our high heats resistance wear parts.  Equipped with a ball joint and lightweight “Bikox® LW” cable assembly, and exchangeable and 360° rotatable torch neck, this welding torch allows for relaxed welding in every position.
  • TH6D Optical Seam Tracking: The TH6D Seam Tracker from Scansonic provides real time data with touch-less recording and measurement of weld components and is the best way to obtain a perfect welding seam.  It will work for all standard seam shapes, and is suitable for all standard surfaces including aluminum and stainless steel.  With an optical filter to prevent falsified measuring results, and a splashwater proof-housing, the Seam Tracking from ABICOR BINZEL is perfect for automotive and OEM manufacturers.   Check out this video of the TH6D in action!
  • ABIROB “Endless Rotation”: A product so new we have still yet to name it, this innovation of our already proven ABIROB Robotic Torch line has a full, endless 360o swanneck/nozzle rotation without torsional stress of the cable assembly. This means faster and easier robot programming with less reorientation movements. The lower program cycle time means less cost and less time spent to finish the job at hand. This new ABIROB comes equipped with an equal tool center point for wire brake option and utilizes standard ABIROB spare parts and consumables. We’ll be showing the rotating action of this groundbreaking new robotic torch technology at our FABTECH booth!

Be sure to come by Booth N4704 to see live demonstrations of these products among others including our Electronic Welding Regulators, pioneered by Regula and carried by ABICOR BINZEL.  For the latest show news and information, follow us on Twitter and LinkedIn.

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Optimizing Shielding Gas Consumption Improves Welding Efficiency

In today’s manufacturing world, greater focus is being placed on maximizing the efficiency of all processes and operations on the plant floor.  When it comes to welding, shielding gas consumption is a central issue facing welding engineers and plant managers as they seek efficient and cost-effective manufacturing processes. As gases are not visibly consumed during the welding process and often their usage is not tracked and gauged as vigorously, it is a more difficult “part” to keep track of in it’s usage.  Failing to track this, however, leads to increased and unnecessary costs being spent on gas, shorter lifetimes on the tanks that store them, and increased  handling costs for having to shuffle out tanks with more regularity.

Solutions exist that save gas consumption with outstanding results. Electronic Welding Regulators, pioneered by Regula and carried by ABICOR BINZEL, are one of the most cost-effective and easy to implement solutions to save on shielding gas consumption.

 

Electronic Welding Regulator from ABICOR BINZEL

How It Works:

The EWR is a device that controls the flow of shielding gas for arc welding.  When the welding process begins, the gas that is between the outlet of the EWR and inlet of the gas solenoid is set at a predetermined pressure in a non-flow state.  The EWR monitors this set pressure level and maintains it during the non-flow condition.  The gas is stored in the section of hose between the EWR outlet and the gas solenoid inlet, and the length of that hose determines the required gas pressure.

After the solenoid is opened the pressurized gas is then released into the welding torch, purging the torch of moisture that may have developed in the gas line during the non-welding condition.  During the actual welding cycle, the EWR monitors the welding current and meters shielding gas based on the amount of current in the welding arc.  The gas current is applied via a standardized curve within the unit and flow can be added or reduced by changing the start point of the curve.

Benefits of the EWR: 

Using an Electronic Welding Regulator offers  multiple advantages that will improve your welding operation.  From up to a 60% saving on shielding gas, to increased process stability, improved welding arc due to gas flow consistency, and longer tank lifetimes, the EWR will make your welding process more economical and efficient. Using the EWR will also allow for a stronger and more stable gas flow as opposed to the standard gas flow without it.  It can also be used on bulk systems as well as bottles if the gas pressure is controlled between 45 and 65 PSI.  With the EWR Pro Display Unit the gas usage and pressure can be viewed with additional information displaying data that would suggest leakage and pressure issues as well.  In the video below, we demonstrate the difference of welding with the EWR and without it.

Visit our website to get more information about our welding products and technology for the welder’s world or contact us.

We also have an ROI Calculator that you can use to compared your current gas usage with an EWR and the potential cost benefit.

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The Rise of Aluminum Welding in the Auto Industry

The drive to make vehicles lighter and more efficient while retaining durability and usefulness has led to a push to increase the use of aluminum in the building of vehicles, more so than ever before. While aluminum has been a key material in vehicle production for nearly a century, recent changes by major car makers such as General Motors and Ford have really increased the use of it.

Alloy wheel repair

The Advantages of Aluminum

The strength of aluminum in comparison to its weight allows for a massive weight reduction in the new Ford F-150 series, resulting in a truck that weighs 700 pounds less than the previous version. This allows for the use of smaller, more fuel efficient engines without sacrificing towing or hauling capabilities. Aluminum also helps to improve crash performance, and by utilizing advanced welding, stamping, and adhesive processes, can also help to reduce noise.

Another advantage is that aluminum is one of the easiest and fastest materials to recycle, and it is infinitely recyclable. This allows scrap material created through the stamping process to be returned to the manufacturer in a closed-loop supply chain. This not only saves resources, but saves production cost as well.

Production Adjustments

Of course, such a drastic shift in the materials used in vehicles requires changes to the manufacturing process. Obstacles exist when introducing aluminum processes into an automotive production. Since the metal itself is thinner and lower gauge, things like metal stamping is more difficult to do, and joining techniques require different processes and technologies steel does not demand. The margin for error when using aluminum is far, far more pronounced.

An old saying in the engineering and automotive world is “never use a screw where a spot weld will do.” While some manufacturers such as Ford are spending the money to completely retool assembly plants to fasten their aluminum pieces with rivets and industrial adhesive, GM has taken a different route. By modifying current production lines, and bringing in new equipment to support the integration of a new metal, GM has adapted their existing robots and welding guns to weld aluminum by adding coolant lines to keep temperatures lower, and by using copper caps that help to disrupt the oxide on the surface of the aluminum, creating stronger welds. This leads to saving on the capital investment while also preventing down-time, plus the safety and security of welds that are more reliable than a screw or rivet.

ABICOR BINZEL  was one of those firms that helped GM in the introduction of new laser equipment to help them integrate aluminum into their production operation. As part of the team that brought the process to GM, we likewise leveraged both the technical expertise of GM and our own product specialists to determine the best solution for bringing the tactile seam tracking process to play. The ALO3 system, which tracks the weld seam by measuring input from the aluminum fill wire, allowed for a precise and repeatable aluminum weld. With the spot-to-wire aligned being so critical in aluminum compared to steel because the difference goes from millimeters to 10ths of a millimeter, it’s critical to have the correct setup and process control.

For more information about our laser products and how we can help you weld a variety of materials, contact us.

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New Threshold Limits for Manganese

Fusion welding and pressure welding processes both produce visible smoke and fumes that contain harmful metal fume and gas byproducts that can be hazardous to a welder’s health. Manganese oxide has gained so much attention as a hazardous element found in welding fumes that it has warranted a closer study of its side effects. The American Conference of Governmental Industrial Hygienists (ACGIH) has revised previous opinion of what the safe level of manganese ingestion is considered to be and has made new recommendations to the levels that welders should be exposed to.

The Changes That You Need to Pay Attention To:

Most industries still peg the allowable exposure limit at 0.2 milligrams per cubic meter, or mg/m3, over an eight-hour work day. The ACGIH has now issued a report that tags allowable Manganese exposure at only 0.02 mg/m3 if worker health is to be maintained. Extensive contact with manganese particulate matter that breaches this new safety limit can lead to neurological processing disorders, tremors, general weakness and lethargy, and even paralysis.

A further complication in this regard is the two tiers of monitoring and supervision prevalent in the United States. Per the federal mandates, Permissible Exposure Limit (PEL) for manganese compounds is 5 mg/m3, but if industries operate in states where the responsibility of ensuring compliance is delegated to state sponsored health and safety organizations with stricter codes and guidelines, then there is an imminent need to align with their specifications as well to avoid fines or shutdowns.

How Can Businesses Re-Think Manganese Exposure Strategy?

With the drastic decrease in allowable exposure over the workday, most current factory ventilation systems are no longer adequate. Manganese adds strength and hardness to manufactured products. It also makes steel impervious to the depredations of corrosion. Due to these factors, it is almost irreplaceable as a part of industrial manufacturing, and a need exists for products that limit welder exposure to manganese.

Abicor Binzel is one of the very few welding manufacturers in the United States that presents two portable and innovative products that can assist in welding fume ventilation:

With_RAB

MIG/MAG torch with fume extraction

The solid and compact Fume Extraction Systems FES-200 & FES-200 W3 with auto operation capability allows for use when actual welding is underway to save energy and reduce welder fatigue and welding downtime. The W3 is in fact one of the only Fume Extraction system on the market certified for Chrome and Nickel content welding by the IFA. Where the FES takes care of overall high vacuum extraction, the Fume Extraction Torch RAB GRIP TA hits the problem closer to the source. Small and easily maneuverable it directly sucks Manganese oxide fumes from the welding spot when they are being emitted as a by-product of the process. The two products in conjunction ensure that you can stick to newer and revised exposure guidelines without compromising productivity or the health and well-being of your welders.

For more information on the products we offer and how they can help you visit our website or contact us here.

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The Welding Revolution on the Horizon

Welding is one of the most important activities associated with manufacturing. It requires precise technology and trained professionals to perform it, often meaning formal certification or years of apprenticeship. Both the welding and manufacturing industries face problems finding qualified workers though as the demand for their expertise continues to increase.  As the innovative leader in welding and metal joining technology, ABICOR BINZEL understands the growing need for more qualified workers, and have been working to publicize the opportunities available in the welding industry.

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A reason why the demand for qualified workers is growing:

Baby Boomers Leaving the Workforce

The largest generation before the inclusion of the millennials in the workforce, baby boomers are retiring in record numbers. It is estimated that 10,000 boomers will leave their professional lives behind every day through the year 2030. The Gen Xers who succeed the most important workforce to date do not have the necessary numbers to fill in the spots that are being vacated so rapidly. This means employers within the welding and manufacturing industry must look to millennials to embrace welding for the essential skill that it is and complement the existing workforce.

Events Promoting Welding and Manufacturing

Floor jobs received little interest among the millennial workforce dating back to just a couple years ago. Production was viewed as a monotonous career with little prospect of advancement and even lesser job perks. But thanks to concerted drives like Manufacturing Day, and the excitement around the recent wave of re-shoring that has resuscitated the US manufacturing sector, perceptions have changed. With innovative companies like Google and Tesla trying to disrupt sleeping industries like automotive and aeronautics, more and more millennials are willing to be the part of a highly skilled and trained group of workers who will hand shape a golden economy for the country and reap rich rewards for their efforts in order to be part of that change.

ABICOR BINZEL is always looking to promote the welding industry, and have worked with the American Welding Society (AWS) to spread awareness about the critical role played by welding in metal fabrication, which is the foundation of the modern world as we know it.  Our participation in and sponsorship of events like FABTECH work to further the promotion and viability of welding and manufacturing, and position the industry as one of innovation and cutting edge technology.

The End Result

Thanks to the contributions of the government and other stakeholders, interest in welding has sparked again. The Cincinnati State’s Harrison Campus has expanded enrollment in its high demand 15 week accelerated welding program and the intake of its two-year degree has also tripled. There has been the recent addition of a $700,000 lab with 12 pods that instruct a new generation of aspiring welders in the science of Shielded Metal Arc Welding, Gas Tungsten Arc Welding, Gas Metal Arc Welding and Flux Cored Arc Welding.

For more information about work as a worldwide manufacturer of arc welding and cutting torches, visit our website.

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ABICOR BINZEL Adheres to ISO Standards for Quality

Quality is very important to everyone at ABICOR Binzel.  We believe strongly in making sure our customers are satisfied with our products and services. This permeates our business operation through every level to ensure that Technology for the Welder’s World is an ethos everyone understands and strives for in their day to day. We have instituted policies and procedures to make sure we produce innovative and quality products. To that end, ABICOR Binzel was the first pure manufacturer of welding torches to be awarded the certificate in compliance with DIN EN ISO 9001 for quality management.

Iso 9001 certified stamp

What is ISO?

The International Standards Organization (ISO) is a non-governmental organization which includes 162 national standards bodies. Each membership body has leading professionals in their industries who share their expert knowledge to design voluntary and market relevant international standards that offer support and innovation to global challenges. This ensures all products and procedures that are ISO certified are created with quality, safety, and efficiency in mind.

What does DIN EN ISO 9001 Cover?

DIN EN ISO 9001 is a family of quality management standards that form the basis for quality assurance and quality management.  Being certified shows the competence and performance capability that ABICOR Binzel has achieved.  To achieve this certification, an in-person audit is performed at our corporate and production facilities all across the world to review our processes regarding the reduction of waste, product liability and product safety, product and process development, and monitoring of quality-related costs.

Benefits of being ISO certified?

In manufacturing being ISO certified is almost a mandate. It is difficult to credibly do business with other companies in the manufacturing world who are not ISO 9000 or ISO 90001 certified. The legitimacy that comes with such certification means your products and practices have a level of conformance that can complement and are compatible with other similar manufacturing products. It’s crucial to the viability of your business among your peers.

The benefits of ISO certification also includes cost savings which can be passed onto the customer because of the aforementioned product compatibility, as well as helping to identify issues in operations and streamline them.  The manufacturing process becomes more lean and streamlined as excess and redundant processes are removed. There are also environmental benefits because ISO standards address any issues that may have a negative impact on the environment, preventing and eliminating waste and pollution that may be released, which aligns with ABICOR Binzel’s existing environmental policy in regards to reducing waste and being conscious about our impact on the environment.

Becoming ISO certified has allowed us to improve our processes at ABICOR Binzel, and make sure we can offer the best possible products and services to our customers.  For more information on the ISO-certified products we can offer you, contact us here.

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The Importance of Safety When Operating Welding Torches

Welding is an incredibly useful skill, and can be used in a variety of industries of manufacturing. With the demand for welders increasing on a global scale, more and more people are getting into the field. At Abicor Binzel we offer a wide variety of welding torches to fit your needs and requirements. One of the first things any welder should know though, are the safety features and procedures that you should have in place for your welding projects.

worker with protective mask welding metal

Safety Tips

  • Dress for Safety: The correct protective wear is necessary for safe welding conduct. This includes clean clothing to avoid providing grease or oil that my potentially catch fire. Eye protection and a welding helmet with the proper grade filter lens should always be worn in addition to protective gloves. These items help to prevent burns and damage to your eyes and skin.  Protective hearing devices should also be worn to ensure protection if noise levels exceed OSHA standards.
  • Check Your Area: Make sure your work area is clear of combustibles, to avoid a stray spark that could potentially ignite a fire. Protective screens and barriers should be considered to prevent a stray spatter or arc flash rays from causing damage to you and people around you.
  • Watch Out for Electricity: Electrical shocks can be deadly, so you need to make sure that all electrical parts are labelled, and that you never touch a live part. Any time you need to hook up or change electrodes, contact tips, or other parts that require electricity, make sure that the power source is disconnected.
  • The Air You Breathe: Many of these safety worries we can see, and are easy to remember, but we often forget about taking care of the air we breathe while working. Fumes and gases created by welding can deplete air quality, causing injury and long term health conditions. Always keep your head out, and away from the fumes, and wear an air-supplied respirator in confined areas or when the breathing air is not safe. Also make sure your work area is well ventilated with fans and air extractors for enclosed areas.  Fume extraction systems like our FES-200 and FES-200 W3 are perfect for this as they remove the fumes at the source using when used in conjunction with a fume extraction MIG welding torch like those in our RAB Grip TA series.

Make sure that you, as well as your colleagues, stay safe when they are performing their welding tasks. Talk to our team at Abicor Binzel about safety equipment, training, and features to go along with your welding gear.  For the latest company news and information follow us on Twitter and LinkedIn

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