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PWL#101B - Resources on Welding Process Comparison, Cost Reduction, Selection, Competition,Joint Req
January 15, 2012
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Mid Month Bulletin No.69
16 January 2012

PWL#101B - Resources on Welding Process Comparison, Cost Reduction, Selection, Competition, Joint Requirements, Waste Reduction, Accessory Equipment, Economics, Optimization, record keeping, analyzing performance, real consumable costs, redesign for economy, automation, robotics, Ship Cost Reduction and much more...

Mid January Bulletin

16 January 2012 - Resources on Weld Cost Reduction - Bulletin 69

Resources on Welding Process Comparison and Cost Reduction

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A longtime PWL Reader who contributed a few interesting articles in the past, spurred by a question of the recent Questionnaire (See: PWL#100), kindly suggested to dedicate some more space to:

Process Comparison and Cost Reduction Articles

The result is the present Mid Month Bulletin No. 69, issue 101B of Practical Welding Letter for Mid January 2012. I hope this list provides useful guidance to readers in search of solutions, and also an encouragement to other readers to take the initiative to suggest new subjects of interest to them.

One should accept the obvious fact that, by ignoring the real costs incurred in any fabrication, including welding operations, it is impossible to pin down waste and reduce it.

Cost Estimate should be done before launching any production line, to get the baseline against which to compare actual costs. This will give a measure of the real performance and of the achievable improvements.

It appears that the search for waste is not the first and foremost priority of most of Managements. It is a pity that the task of looking for and reducing waste is looked at with fear and distrust.

See also the page on Welding Cost Estimate.

I am pleased to give here advance notice of an article, to be published in the next issue PWL#102, titled Process Optimization & Innovation, of my friend Naddir M. Patel of

He is an Expert with a proven history of successful performance improvement in fabrication environments. He can be contacted for consultancy and help through his website given above.

The addresses reported hereafter were live and correct at the time of their publication. There is no guarantee that they will always be so, because they are administered by the sources themselves and are under their control.

Note: References to articles or other documents are given here in one of two forms. If the links are "live" (usually underlined or otherwise highlighted) they are operated with a click of the mouse.

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If the information is important to you, you may save the selected pages in a suitable folder on your Computer for easy reference. You are welcome to forward this page to those of your friends who may profit of this information.

* * *


Welding Process Comparison Study (11 pages)

Plastic Joining: Process Comparison
- How Laser Plastic Welding Stacks Up to the Competition

Resources on Welding Economics
Click on PWL#051B.

Fatigue Characterization of Automotive Steel Sheets (6 pages)

Process Comparison (PAW - EBW - LBW)
(Advantages vs. Disadvantages)
Click on PWL#021.

Friction Welding Comparison
Sorry! The link was removed by the source:

Dimension™ NT 450 Competitive Comparison

Tandem MIG Process
Lincoln 1.

Experimental comparison of mig and friction stir welding processes
for EN AW-6061-T6 (Al Mg1 Si Cu) Aluminium Alloy
(10 pages)

Comparison between AC and MF-DC resistance spot welding
by using high speed filming

Weld Procedure Variables Comparison Sheet for Structural Steel Codes (5 pages)

Comparing flash and butt welding
The Fabricator.

Welding Process Effects in Weldability Testing of Steels

Welding on the Farm: Selecting a Welding Unit

Comparison of orbital and linear vibration welding of thermoplastics.

Remote welding impacts auto manufacture

The welding process impact on residual stress and distortion
(21 pages)

Process Selection for Welding
Lincoln 2.

Reducing Your Welding Costs
Lincoln 3.

Guaranteed Cost Reduction (GCR)
Lincoln 4.

EBTEC Achieves Significant Cost Saving in Joint Strike Fighter
(F-35) Engine Program
Sorry, the link was removed.

One Million Dollar Cost Reduction for Field Pipe Line Welding Crew.

TIP TIG welding is 100 to 500% faster than TIG

Estimating Total Welding Costs

[Note: - The following is reported as an example of
how Management should strive to improve Welding Workforce
Weld Engineer
Sorry, the link was removed.

Welding Optimization

Choosing the Right Consumables to Reduce Welding Cost (4 pages)

Cost Reduction Solutions

Automated welding for job shops

Hybrid laser welding of pipes and the cost effectiveness
compared to conventional welding

Practical Applications for Hybrid Laser Welding

Fixtures and Integration for Robotic and Automated Welding
(Presentation - 39 Frames)

Documents for Ship Cost Reduction Study Guide
(Presentation - 12 Frames)

Cost Reductions and Product Consistency Improvements Using
Unannealed High-Frequency/Solid State (UHFSS) Welded
409 Stainless Steel Heat Exchanger Tubing
(12 pages)
Atlas Steel.

Spot Welding: Still in the Driver's Seat


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