What are the main errors during the arc welding processes and how can we avoid them?

Failures cause loss of competitiveness and can lead to serious accidents


When arc welding processes are not performed correctly, too many damages can occur in industries and in society. Cases of oil platforms that collapsed due to failures in welding, for example, are not unusual. Even some traffic accidents can be caused by errors generated by the most diverse manufacturing discontinuities.

Inside the companies, failures in the welding processes can compromise the integrity of employees and affect the work environment. The errors also cause loss of competitiveness of the industry, as they reduce productivity rates expressively and negatively compromise the costs of the product, the project or the work.

In general, there are four main errors made during the operations in arc welding processes. They are:

1. Ignore the main features of the general process regarding metallurgical properties, applicability, performance, productivity, advantages and limitations.

2. Misuse of equipment due to lack of training and technical training of the professionals involved in the operation (welder, inspector, among others).

3. Incorrectly applying the process with parameters and/or equipment not appropriate to meet the features of the process, blocking the best results in performance, arc stability, productivity and operational comfort required by the welder.

4. Use welding consumables, electrodes, wires, submerged arc flux, and incorrect or even poor protection gases.


How to avoid the most frequent errors

To avoid errors in welding, it is essential to know the importance of providing technical trainings to those involved directly or indirectly in the activity. Knowing the features, advantages, benefits and limitations of applications is also critical.

Another tip is considering welding equipment as a system, understanding and knowing the various points of vulnerability that may exist. It is essential to observe the technical and operational aspects of all products in order to achieve the best performance, and not only evaluate the "price" aspect. Cables, torch, electrode holder, contact tip, earth clamp, feeding cable and power cable are some of the points that need to receive redoubled attention in a system for arc welding.

An interesting comparison with this scenario is a hydraulic system. A pipe with water leakage must be quickly repaired or it will generate losses. An arc welding system is very similar. Losses due to poor electrical contact and poor quality torches generate relevant losses. We call these failures "hidden costs".


Sumig offers complete solutions for welding and cutting

Sumig offers an excellent portfolio of products that meet the most demanding welding requirements. The company operates in numerous segments, such as Agricultural, Road, Metallurgy, Machinery, Autoparts, Reseller, Boiler, Metallic Structures, Furniture, Shipyards, Bike/Moto, Foundry, Construction, Locksmith, among others. The technology and quality of Sumig products, as well as technical support, reach the expectations of all interested parties.

An example of brand innovation is the Intellimig monitoring and control system. The technology offers to the customer the control of their welding operations, preventing the error, controlling the quality and assisting the welder. When using Intellimig, companies are not tied to a specific supplier of welding equipment, since the system can be used in almost all welding equipment and not only those provided by Sumig.

From the anti-spatters product to the robotic cell, Sumig treats the solution as technical rather than commercial. The focus of the brand consists on meeting the need of the application, not forgetting to generate cost reduction, increase productivity and maintain the quality of the welding performed. Get to know all Sumig solutions on our website. 


by Ubirajara Costa | Branch Manager

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