Keeping an Open Mind and Reaping the Benefits: How One Company Reduced its Downtime and Costs Through a Simple Product Trial

When you have a company that fabricates its projects by the tons and measures its man-hours by the thousands, downtime simply isn’t an option. The welding operators and supervisors at Brooklyn Iron Works know that fact better than most. The Spokane, Wash.-based company, whose steel fabrication spans from bridges in Alaska to projects in Antarctica, tackles some of the highest-profile, high-inspection jobs around. And they rely on some good old-fashioned teamwork, among other attributes, to meet their deadlines.

“Everything we do is a team effort,” QA Manager Phil Zammit explains. “We’re a good company with skilled employees and good management. It makes us a premium company here in the Northwest.”

It also makes them a reputable one. Brooklyn Iron Works doesn’t maintain a sales force, but instead relies — and successfully so — on its reputation and word of mouth to generate business. Scott Allen, the company’s general manager, explains that they are invited to bids based simply on the quality work they do and the timeliness in which they do it.

Last year, Norco Gas & Supplies representative Tim McGrath approached Zammit and Allen with a proposition to make their welding operations even better: a two-week trial of Bernard Centerfire™ consumables on their existing MIG guns. According to Zammit, they had tried Bernard products years before and didn’t think they were the right fit for their application. Still, he decided to keep an open mind and agreed to the trial. Two weeks later, he invited McGrath to convert the front-end of all 25 of the company’s MIG guns to Centerfire consumables and shortly thereafter, converted to Bernard’s Q-Gun™ MIG guns too.

The reason? Less downtime.

The Projects and Challenges

Brooklyn Iron Works, according to Allen, fabricates projects ranging from 650 to 2,000 tons or more, including fracture critical structural components for bridges, demand-critical welding on columns, beams and moment connections bound for seismic locations, like California. Not surprisingly, the company maintains a workforce of highly skilled certified welders certified to the AWS D1.1 (Structural Welding Code – Steel), D1.8 (Structural Welding Code – Seismic) and D1.5 (Bridge Welding Code).  Many projects take between nine months and a year from start to finish. Depending on contract and/or code specifications, every weld at Brooklyn Iron Works is visually inspected and oftentimes includes 100 percent NDE (nondestructive examination) including MT, UT or RT. Others undergo random NDE testing for quality monitoring purposes. The company maintains a staff of certified welding inspectors (CWIs), as well as hosting contracted NDE inspectors, to manage these tasks. They also have a cleaning and painting facility to finish products after welding and prior to shipment to customers.

Gaining access to the weld joints is one of the biggest challenges welding operators at Brooklyn Iron Works encounter while creating these welds. They weld mostly structural steel grades, with the majority being A36, A572 Grade 50, A500 and A709 steel including weathering types. Thicknesses range from 1/4 to 2-1/2 inches. On deep and tight joints, reaching the root of the joint for the initial root pass requires not only the right type of MIG gun and nozzle, but also welder dexterity. With the company’s previous consumables, welding operators often had to extend their electrode stickout as far as 2 inches to access the joints, a practice that risked generating porosity since it could compromise the necessary shielding gas coverage.

Another challenge the company faced was the occurrence of burnbacks, the formation of a weld inside the contact tip, when using their old brand of contact tips. Brooklyn Iron Works welding personnel run their weld beads at high amperages (300 to 400 amps) using typically .052- or 1/16-inch FCAW wire diameters, which often proved too harsh on their previous contact tips. They would loosen after routine welding, causing the wires to arc back and create the burnback.

The trial of Centerfire consumables gave Zammit and his team of welding operators a solution to these two problems—and it led to a MIG gun conversion that provided some additional benefits, too.

The First Solution

When McGrath initiated the trial of Centerfire consumables at Brooklyn Iron Works, he started by installing them on just two MIG guns, using a conversion adapter offered by Bernard. Zammit and his welding operators quickly realized that the design of the Centerfire consumables provided a better solution for their welding operation.

The Centerfire nozzles they trialed, and now use, feature a tapered design that stays fixed flush with the end of the contact tip and allows welding operators to reach into the deep weld joints without having to extend their welding wire as much. As a result, the welding operators can gain better gas coverage and lessen the risk of porosity. The Centerfire consumables also include a built-in spatter shield that acts as an additional gas diffuser and ensures a more consistent gas flow, a feature that Zammit particularly likes.

“These consumables direct the gas exactly where we need it,” he explains. “It keeps our gas shielding coverage right at the weld, even when the doors are open or we have a breeze. We’ve never had a huge problem with porosity, but now we have even less of one.”

Just as importantly, Zammit and his welding operators have almost completely resolved their issue with burnbacks. Compared to the company’s previous contact tips, which threaded into the diffuser and tended to loosen after welding, the Centerfire contact tips “drop in” the diffuser and are held in place by tightening the nozzle. This non-threaded tip design features a tapered base and large diameter seat that helps generate consistent electrical conductivity and heat transfer—and it stays in place during welding.

We rarely get burnbacks anymore with the Bernard contact tips, before we had a substantial amount of downtime. And that’s money. It’s lost arc time for tip maintenance.

Phil Zammit Quality Assurance Manager, Brooklyn Iron Works

On the few occasions when a burnback does occur, Zammit notes that the Centerfire contact tips can be easily removed— without tools— and changed because of the threadless design.He also goes on to explain that the company is saving money by having to replace fewer contact tips. By his calculation, Brooklyn Iron Works now uses about a third fewer contact tips than before.

Finding Additional Benefits with New MIG Guns

Shortly after converting their front-end consumables, Zammit and his welding operators also decided to convert to Bernard MIG guns. They now use 400-amp, air-cooled Q-Gun MIG guns with 15-foot cables and have, since the conversion, found additional ways to reduce downtime.

According to Zammit and Maintenance Supervisor John Dahl, the maintenance on their Q-Gun MIG guns is much simpler than with the competitive guns they used previously. Changing the neck or liner on those guns required an Allen wrench to remove setscrews on the front and backend of the MIG guns, a process that Dahl says required disassembling the MIG gun and could take nearly an hour to complete.

To change the necks on the Q-Gun MIG guns Dahl simply unscrews a plastic ring surrounding the neck by hand and inserts the new neck or liner. It takes less than five minutes. And he finds that he doesn’t have to conduct maintenance as often, either. In fact, he said that one of the Q-Gun MIG guns has been used with the same liner for a year.

“Maintenance on these guns is so much easier and quicker now,” says Dahl. “Plus, we’ve gotten good feedback from the welding operators in terms of the neck options on the Q-Guns.”

The Q-Gun MIG guns have necks available in fixed, rotatable and flexible options in various lengths and bend angles, with the rotatable versions being able to changeover without tools. According to Zammit, these neck options help the welding operators better accommodate the varying welding angles they encounter on projects. They can reach the weld joints easier and reduce downtime to address issues like wrist fatigue. Welding operator Ricky Curtis agrees — especially when it comes to using the flexible neck versions of the Q-Gun MIG guns

“I can bend the neck in any direction I need,” he explains. “Even around the corners. I like that the gun does the work for me, instead of my wrist.”

Zammit and Allen also like that the welding operators are more comfortable and that it is taking less time to maintain the guns. Simply put, more arc-on time means better productivity.

Reaping the Benefits

Keeping an open mind isn’t always easy. It’s often human nature to stay with the routine of “doing things as they’ve always been done.” But sometimes, taking a chance can yield unexpected benefits. Brooklyn Iron Works clearly learned this lesson when they agreed to the trial of Bernard consumables. Now they are reaping the positive results that come with it, and passing those results on to their customers.

MIG Gun Consumables: Tips to Extend Life

Consumables for the welding gun can significantly impact the productivity and welding quality in an operation. This makes it important to keep consumables properly cleaned and maintained, to help minimize unplanned downtime, extend consumable life and optimize performance.

The Heat Factor

The heat produced in the welding process can have a significant impact on the cleanliness and longevity of MIG consumables. Processes like pulsed MIG and/or higher amperage applications tend to subject consumables to higher levels of heat, as do applications in which there is a large amount of reflective heat. Those include applications with tight tooling or those that require welding in restricted areas.

The hotter the consumables become during the welding process, the softer the material (usually copper or brass) becomes, resulting in a surface area that is much more prone to accumulating spatter and failing prematurely.

To avoid such problems, it is important to determine the best consumables for each application and consider how they will be managed throughout the course of a welding shift. For example, high-amperage applications (those above 300 amps) most often benefit from using heavy-duty consumables because they have greater mass and are capable of dissipating the heat more readily. However, if the welding procedure dictates that the contact tip must be changed frequently, a standard-duty contact tip may suffice. The goal is for companies to determine which consumables — heavy- or standard-duty — are most capable of withstanding the duty cycle and heat of the application. A reliable welding integrator can often help with the selection.

The Anti-Spatter Solution

Using an anti-spatter compound can help keep MIG consumables clean on both semi-automatic and robotic welding applications; however, it must be used sparingly. On a semi-automatic application, welding operators should dip only the front inch and a half of the nozzle into the anti-spatter compound. Submerging the nozzle in the anti-spatter compound can saturate the nozzle’s fiberglass insulator and also potentially plug up the gas holes on the diffuser. This build-up may cause the nozzle to fail prematurely or result in porosity in the welds due to the unbalanced gas coverage. In robotic applications, only the minimum amount of anti-spatter compound required for the application should be used. Using too much can cause build-up on the consumables and/or cause debris to accumulate and clog the nozzle, leading to poor gas coverage, inconsistent electrical conductivity or shortened consumable life.

Another important way to combat spatter is to inspect the nozzle for build-up on a regular basis and clean it with a soft wire brush or spatter-cleaning tool as needed. Welding operators should never hit the nozzle against the tooling or work piece to loosen spatter. Doing so can dent, misshape or compromise the smooth surface finish of the nozzle, which creates greater areas for spatter to adhere to and reduces the life of the consumable.

Proper Storage and Handling

Always keep MIG consumables in their original packaging until they are ready for use. Opening them and placing them in a bin can lead to scratches or dents that allow spatter to adhere and will ultimately shorten the products’ life. Similarly, removing contact tips or diffusers from their packaging and storing them in open or dirty containers can cause dirt and oil to accumulate in the threads, which can impede them from properly seating together. Also, companies should always keep storage containers for new consumables separate from those for discarded ones to avoid selecting an old contact tip or nozzle that may have dents or scratches and be prone to spatter accumulation. Finally, welding operators should always use clean gloves when handling or replacing contact tips, nozzles and diffusers to prevent dirt, oil or other contaminants from adhering to them.

Establish and Maintain Good Connections

Installing MIG consumables correctly and inspecting them periodically for good connections minimizes the chance of poor conductivity and with it, spatter accumulation or premature failure. Welding operators should always follow the GMAW consumable manufacturer’s suggestions for contact tip and gas diffuser installation, using a pair of channel lock pliers, welpers or other such recommended installation tool. Never use wire cutters or side cutters — too much pressure from these tools can damage the inside diameter of the contact tip, which leads to poor welding performance and a shortened lifespan. Also these tools tend to scratch the surface of the consumables leaving marks that attract spatter.

A good rule of thumb is to hand tighten the contact tip until it is fully seated into the diffuser, then grip the contact tip with an appropriate tool as close to the base as possible, tightening it 1/4 to 1/2 turn past finger tight. This procedure helps ensure a good connection that minimizes electrical resistance, overheating and damage to the consumables, as well as excessive spatter accumulation. Follow the same procedure for installing and tightening the diffuser so that it fully connects with the neck. Also note, some contact tips available in the marketplace can be installed and held in place by hand tightening the nozzle. Check the manufacturer’s recommendation for proper installation instructions.

Inspect consumable connections regularly to ensure that they are secure.

Trim Liners Correctly

An improperly trimmed and installed liner can cause a host of wire-feeding problems that lead to downtime to rectify. It can also affect the performance of MIG consumables, how clean they stay and their longevity. Cutting a liner too short can cause the liner to be misaligned with or in the gas diffuser. The result is a welding wire that feeds off-center, leading to premature contact tip failure. Liners that are too short can also lead to the build-up of debris between the liner and retaining head, which causes wire feeding issues and poor weld quality. In some cases, the gap that is present between the gas diffuser and liner when a liner has been cut too short may cause the welding wire to catch, resulting in small shavings that can plug up the contact tip and cause it to fail quickly. A liner that’s too long can cause kinking that again leads to wire-feeding issues that shorten the life of the contact tip. Always make sure that to remove any burrs or sharp edges after cutting a liner to ensure smooth and consistent feeding of the welding wire.

Recess/Extension	Amperage	Wire Stick-Out	Process	Notes
1/4-in. Recess	> 200	1/2 – 3/4in.	Spray, high-current pulse	Metal-cored wired, spray transfer, argon-rich mixed gas
1/8-in. Recess	> 200	1/2 – 3/4in.	Spray, high-current pulse	Metal-cored wired, spray transfer, argon-rich mixed gas
Flush	< 200	1/4 – 1/2in.	Short-current, low-current pulse	Low argon concentrations or 100 percent CO2
1/8-in. Extension	< 200	1/4 in.	Short-current, low-current pulse	Difficult-to-access joints

Welding operators should always consult with the liner manufacturer’s recommendation for proper trimming and installation instructions. It is also important that they wear gloves when handling the liner and avoid dragging it on the ground to prevent debris from being introduced into the MIG gun. Such debris can lead to weld contamination and/or poor consumable performance.

Mind the Contact Tip Position and Nozzle Size

The position of the contact tip (extended or recessed) affects how well consumables last, along with how clean they stay. So too does the nozzle used in conjunction with a specific contact tip and the wire size. The farther the contact tip extends from the nozzle, the closer it is to the arc and the more prone it is to reflective heat. The result is a greater tendency toward spatter accumulation and a greater opportunity for burnbacks. Using a recessed contact-tip-to-nozzle relationship when possible can minimize this problem and provide better shielding gas coverage at the same time.

For companies with applications that require access into restricted areas, it is important to select a nozzle that provides that access, but isn’t tapered so much that it minimizes the space around the contact tip. If there isn’t enough space for shielding gas to flow out of the nozzle, it can cause the shielding gas to hit the work piece and begin jetting back and/or swirling. The result is the pulling of oxygen into the weld pool and an increase in spatter. Too, the smaller the bore size on the nozzle, the more prone it is to absorbing heat (because there is less mass to that portion of the consumable) and having spatter adhere to it.

Other Considerations

As a general rule, companies should select the largest consumable that will work for the application and provide the necessary joint access. Larger consumables are more able to resist heat and spatter build-up, and they often last longer as a result.

Selecting consumables with the right material for the application is important, too. For example, brass nozzles tend to resist spatter well and are good for lower-amperage applications (100 to 300 amps), whereas copper nozzles are better for high-amperage applications (above 300 amps) or for those with longer arc-on time.

Lastly, companies should always pay attention to the manner in which they manage consumables. When possible, having the same consumables throughout the welding operation can help welding operators better maintain the consistency of the consumable performance and troubleshoot problems more quickly when they occur. The result can be longer-lasting, cleaner consumables that provide more reliable performance and quality.