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<li class="current">5 Benefits of a Switch to Wire Welding Processes in Pipe Welding</li>
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<h1>5 Benefits of a Switch to Wire Welding Processes in Pipe Welding</h1>
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<div class="article-synopsis">Learn how to optimize open root pipe welding with a switch to advanced wire welding processes in shop and field applications.</div>
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<h2>Root pass welding change</h2>
<p>Change can be hard, but leaders in the pipe welding industry are upping their game by changing from the status quo.</p>
<p>Meeting stringent quality requirements and demanding project timelines are critical in pipe welding, both in the field and the shop. Having the capabilities for advanced welding processes when customers call for them means
contractors can capitalize on those opportunities and bid on more jobs.</p>
<p>Approximately 80% of the costs associated with welding are related to labor. Giving welders technology and equipment that improves their productivity can save significant time and money.</p>
<p>Here are five benefits a switch to the Regulated Metal Deposition (RMD®) process for open root pipe welding in shop and field applications can deliver.</p>
<h3 class="wp-block-heading" id="h-5-benefits-of-converting-to-wire-welding">5 benefits of converting to wire welding</h3>
<ol>
<li><strong>Faster process changeover<br>
</strong>Using advanced wire processes like RMD (a modified short-circuit MIG process) and pulsed MIG welding allows for simple process changeover between weld passes with the push of a button.<br>
<br> This greatly reducing switch-over time compared to using TIG and stick welding, which requires changing polarity between each process switch. With
<a rel="noopener noreferrer" href="https://www.millerwelds.com/equipment/welders/multiprocess/pipeworx-welding-system-m00326" target="_blank">PipeWorx 400</a> and
<a rel="noopener noreferrer" href="https://www.millerwelds.com/equipment/welders/multiprocess/xmt-350-fieldpro-system-m30152" target="_blank">XMT® 350 FieldPro™</a> with Polarity Reversing systems, operators can change polarity
with the push of a button — without moving the electrical connection. In addition, RMD and pulsed MIG can provide a one wire, one gas solution that reduces time spent on changeover.<br>
<br> In the shop, a welding system with a dual feeder option allows flexibility to set up each side with any gas or filler metal combination required. This delivers even more time savings in setup and switch over. Operators can
just pick up the desired welding gun and weld.<br>
<br>
</li>
<li><strong>Improved productivity<br>
</strong>RMD and advanced wire processes are much more productive than TIG and stick welding for several reasons.<br>
<br> The wire-fed processes offer travel speeds that are three to four times those of TIG or stick welding. Wire processes are typically easier for new welders to learn than TIG and stick welding, which saves time in training.
In the PipeWorx 400 system and the
<a rel="noopener noreferrer" href="https://www.millerwelds.com/accessories/wire-feeders/arcreach-suitcase-feeders-m30153?product-options-title=arcreach-smart-feeder-bernard-pipeworx-300-amp-gun-pkg-951733#!/" target="_blank">ArcReach® Smart Feeder</a>,
RMD is also fine-tuned for open root pipe and vessel welding. This makes the process more efficient for producing code-quality welds.<br>
<br> Pipe fabricator Dixie Mechanical doubled welding productivity — completing twice as many welds in the same amount of time — with a process switch. The company had been welding stainless steel pipe with a TIG root pass and
argon back purge followed by flux-cored fill and cap passes. They switched to an RMD root pass and eliminated the time-consuming and costly back purge.<br>
<br> Kiewit Power Constructors also increased productivity when they switched to RMD and flux-cored welding for several power plant projects. In some instances where Kiewit previously TIG welded the root pass for P11 and P91
pipe, they used RMD without a purge. For the remaining passes, they used flux-cored welding instead of stick.<br>
<br>
</li>
<li><strong>Optimized arc performance<br>
</strong>The RMD process is engineered with a high-quality arc specifically tailored for open root/joint pipe and vessel welding.<br>
<br> Early prediction of the short clearing enables the power source to quickly reduce the available current. This minimizes the excessive arc force on the puddle and results in a calm, controllable puddle.<br>
<br> The smooth arc and bead profile wets out nicely — helping welders of all skill levels produce high-quality welds.<br>
<br> RMD and advanced wire processes aren’t limited to shop welding applications, either. With the ArcReach Smart Feeder, you get consistent arc performance on the jobsite for multiple weld processes — even when weld cables are
hundreds of feet long.<br>
<br>
</li>
<li><strong>Eliminate back purge<br>
</strong>Using RMD instead of TIG for the root pass on stainless steel and chrome pipe welds may allow operations to eliminate the back-purge process. Back purging provides gas shielding on the back side of the joint while
welding, but it adds significant time and money to the process.<br>
<br> It can require 20 to 30 minutes each time, depending on pipe size, to set up the argon shielding gas and tape the pipe ends for purging. In addition, the argon gas used for back purging adds to consumable costs. Back
purging can also introduce safety hazards to operators who can be overcome by the argon gas and suffer inert gas asphyxia. Eliminating back purge saves time and money and reduces the risks involved with the process.<br>
<br> With RMD, welders can more easily control the weld puddle, welding speeds and heat input. A lower heat input allows the weld puddle to freeze faster. All of these factors combine to result in a less turbulent weld puddle
and smoother shielding gas flow. This allows the gas to push through the open root and protect the weld's back side from sugaring, or contamination. Because the puddle freezes so quickly in the RMD process, such gas coverage is
only needed for a short time — eliminating the need for back purging.<br>
<br>
</li>
<li><strong>Train new welders faster<br>
</strong>As the industry faces a continued shortage of skilled welders, contractors are looking for ways to train new welders faster. This may be especially critical on large plant construction projects that span two to three
years and require dozens of full-time welders.<br>
<br> Compared to stick and TIG welding, wire-fed processes like RMD are generally easier to learn and use, reducing training time.
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<p>A welding process change can deliver big rewards for pipe welding, both in the shop and in the field. An advanced wire process like RMD can help operations improve productivity, train welders faster and produce high-quality welds
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cookies.SessionHTTPgmidSAPIdentifies the logged in user. A unique session ID is
linked to the user so that he/she is identified while navigating the website.
The user is logged out when the cookie expires.1 yearHTTP_GRECAPTCHAGoogleThis
cookie is used to distinguish between humans and bots. This is beneficial for
the website, in order to make valid reports on the use of their website.180
daysHTTPrc::aGoogleThis cookie is used to distinguish between humans and bots.
This is beneficial for the website, in order to make valid reports on the use of
their website.PersistentHTMLrc::bGoogleThis cookie is used to distinguish
between humans and bots. SessionHTMLrc::cGoogleThis cookie is used to
distinguish between humans and bots. SessionHTMLio_tempPower ReviewsUsed to
recognize which type of device the user is using, to ensure the website's
security. PersistentHTMLli_gcLinkedInStores the user's cookie consent state for
the current domain180 daysHTTP_ce.cchCrazyeggStores the user's cookie consent
state for the current domainSessionHTTPce_asset_waitingCrazyeggThis cookie is
part of a bundle of cookies which serve the purpose of content delivery and
presentation. The cookies keep the correct state of font, blog/picture sliders,
color themes and other website
settings.SessionHTMLce_successful_csp_checkCrazyeggDetects whether user
behaviour tracking should be active on the website.
PersistentHTMLPHPSESSIDBlipstar.comPreserves user session state across page
requests.SessionHTTPbscookieLinkedInThis cookie is used to identify the visitor
through an application. This allows the visitor to login to a website through
their LinkedIn application for example.1
yearHTTP__sharethis_cookie_test__SharethisThis cookie determines whether the
browser accepts cookies.SessionHTTPCookieConsentCookiebotStores the user's
cookie consent state for the current domain1 yearHTTPcookietestQualtricsThis
cookie is used to determine if the visitor has accepted the cookie consent
box.SessionHTTPtestcookieMiller ElectricThis cookie determines whether the
browser accepts cookies.SessionHTTPCRAFT_CSRF_TOKENGoogleEnsures visitor
browsing-security by preventing cross-site request forgery. This cookie is
essential for the security of the website and visitor.
SessionHTTPCraftSessionIdGoogleSets a unique ID for the session. This allows the
website to obtain data on visitor behaviour for statistical
purposes.SessionHTTPCONSENTYouTubeUsed to detect if the visitor has accepted the
marketing category in the cookie banner. This cookie is necessary for
GDPR-compliance of the website. 2 yearsHTTP
Preference cookies enable a website to remember information that changes the way
the website behaves or looks, like your preferred language or the region that
you are in.
NameProviderPurposeExpiryTypehasGmidSAPThis cookie stores visitor credentials in
an encrypted cookie in order to allow the visitor to stay logged in on reentry,
if the visitor has accepted the 'stay logged in'-button.6 monthsHTTP
Statistic cookies help website owners to understand how visitors interact with
websites by collecting and reporting information anonymously.
NameProviderPurposeExpiryTypeabNeustarThis cookie is used by the website’s
operator in context with multi-variate testing. This is a tool used to combine
or change content on the website. This allows the website to find the best
variation/edition of the site. 1 yearHTTPSC_ANALYTICS_GLOBAL_COOKIE [x2]Miller
ElectricUsed by Sitecore Engagement Analytics to identify the visitor on repeat
visits to the website.10 yearsHTTP__utm.gifGoogleGoogle Analytics Tracking Code
that logs details about the visitor's browser and
computer.SessionPixelcollectGoogleUsed to send data to Google Analytics about
the visitor's device and behaviour. Tracks the visitor across devices and
marketing channels.SessionPixelAnalyticsSyncHistoryLinkedInUsed in connection
with data-synchronization with third-party analysis service. 30
daysHTTP__qcaQuantcastCollects anonymous data on the user's visits to the
website, such as the number of visits, average time spent on the website and
what pages have been loaded with the purpose of generating reports for
optimising the website content.1 yearHTTP__utmaGoogleCollects data on the number
of times a user has visited the website as well as dates for the first and most
recent visit. Used by Google Analytics.2 yearsHTTP__utmbGoogleRegisters a
timestamp with the exact time of when the user accessed the website. Used by
Google Analytics to calculate the duration of a website visit.1
dayHTTP__utmcGoogleRegisters a timestamp with the exact time of when the user
leaves the website. Used by Google Analytics to calculate the duration of a
website visit.SessionHTTP__utmtGoogleUsed to throttle the speed of requests to
the server.1 dayHTTP__utmvGoogleSaves user-defined tracking parameters for use
in Google Analytics.SessionHTTP__utmzGoogleCollects data on where the user came
from, what search engine was used, what link was clicked and what search term
was used. Used by Google Analytics.6 monthsHTTP_ce.clock_dataCrazyeggCollects
data on the user’s navigation and behavior on the website. This is used to
compile statistical reports and heatmaps for the website owner.1
dayHTTP_ce.clock_eventCrazyeggCollects data on the user’s navigation and
behavior on the website. This is used to compile statistical reports and
heatmaps for the website owner.1 dayHTTP_ce.gtldCrazyeggHolds which URL should
be presented to the visitor when visiting the site.
SessionHTTP_ce.sCrazyeggCollects data on the user’s navigation and behavior on
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website owner.1 yearHTTP_dltQuantcastSets a unique ID for the session. This
allows the website to obtain data on visitor behaviour for statistical
purposes.1 dayHTTP_gaGoogleRegisters a unique ID that is used to generate
statistical data on how the visitor uses the website.2 yearsHTTP_ga_#GoogleUsed
by Google Analytics to collect data on the number of times a user has visited
the website as well as dates for the first and most recent visit. 2
yearsHTTP_gatGoogleUsed by Google Analytics to throttle request rate1
dayHTTP_gidGoogleRegisters a unique ID that is used to generate statistical data
on how the visitor uses the website.1 dayHTTP_tt_enable_cookieTiktokUsed by the
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yearHTTPcebsCrazyeggTracks the individual sessions on the website, allowing the
website to compile statistical data from multiple visits. This data can also be
used to create leads for marketing purposes.SessionHTTPcebsp_CrazyeggCollects
data on the user’s navigation and behavior on the website. This is used to
compile statistical reports and heatmaps for the website
owner.SessionHTTPPugTPubMaticUsed to determine the number of times the cookies
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server efficiency. 30 daysHTTPQ_INTERQualtricsCollects statistics on the
visitor's visits to the website, such as the number of visits, average time
spent on the website and what pages have been
read.PersistentHTMLQSI_ActionSetHistoryQualtricsAssigns a specific ID to the
visitor. This allows the website to determine the number of specific user-visits
for analysis and statistics.SessionHTMLQSI_HistoryQualtricsUsed to detect
whether the user has responded to surveys presented on the website. The purpose
of the surveys are website optimization.SessionHTML__qcaQuantcastCollects data
on the user's visits to the website, such as the number of visits, average time
spent on the website and what pages have been loaded with the purpose of
generating reports for optimising the website
content.PersistentHTMLqcSesQuantcastCollects data on the user's visits to the
website, such as the number of visits, average time spent on the website and
what pages have been loaded with the purpose of generating reports for
optimising the website content.SessionHTMLcetabidCrazyeggSets a unique ID for
the session. This allows the website to obtain data on visitor behaviour for
statistical purposes.SessionHTMLga_#StacklaRegisters a unique ID that is used to
generate statistical data on how the visitor uses the
website.SessionHTTPpersonalization_idTwitter Inc.This cookie is set by Twitter -
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website, such as which pages have been read.2 yearsHTTPtdGoogleRegisters
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by the website operator. SessionPixelln_orLinkedInRegisters statistical data on
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operator. 1 dayHTTPQSI_HistorySessionQualtricsUsed to detect whether the user
has responded to surveys presented on the website. The purpose of the surveys
are website optimization.SessionHTTPvisitedxmt650.2rmdev.comRemembers whether
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daysHTTPyt-player-headers-readableYouTubeUsed to determine the optimal video
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Marketing cookies are used to track visitors across websites. The intention is
to display ads that are relevant and engaging for the individual user and
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displaying targeted ads.3 monthsHTTPtuuid_luImprove DigitalContains a unique
visitor ID, which allows Bidswitch.com to track the visitor across multiple
websites. This allows Bidswitch to optimize advertisement relevance and ensure
that the visitor does not see the same ads multiple times. 3 monthsHTTPumImprove
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to track visitors on multiple websites, in order to present relevant
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movements and various ad providers' bids for displaying user ads.2
monthsHTTPanjAppnexusRegisters a unique ID that identifies a returning user's
device. The ID is used for targeted ads.3 monthsHTTPuuid2AppnexusRegisters a
unique ID that identifies a returning user's device. The ID is used for targeted
ads.3 monthsHTTPad-idAmazonUsed by Amazon Advertising to register user actions
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daysHTTPad-privacyAmazonUsed by Amazon Advertising to register user actions and
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daysHTTPr1AmazonPendingSessionHTTPsambapxidAmazonUsed to track the visitor
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visitor through multiple channels. 13 monthsHTTPtt_appInfoTiktokUsed by the
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services.SessionHTMLtt_pixel_session_indexTiktokUsed by the social networking
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services.SessionHTMLtt_sessionIdTiktokUsed by the social networking service,
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services.SessionHTMLbkpaBluekai.comPresents the user with relevant content and
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facilitate real-time bidding for advertisers.6 monthsHTTPbkuBluekai.comRegisters
anonymised user data, such as IP address, geographical location, visited
websites, and what ads the user has clicked, with the purpose of optimising ad
display based on the user's movement on websites that use the same ad network.6
monthsHTTPCMIDCasale MediaCollects visitor data related to the user's visits to
the website, such as the number of visits, average time spent on the website and
what pages have been loaded, with the purpose of displaying targeted ads.1
yearHTTPCMPROCasale MediaCollects data on visitor behaviour from multiple
websites, in order to present more relevant advertisement - This also allows the
website to limit the number of times that they are shown the same advertisement.
3 monthsHTTPCMPSCasale MediaCollects visitor data related to the user's visits
to the website, such as the number of visits, average time spent on the website
and what pages have been loaded, with the purpose of displaying targeted ads.3
monthsHTTPcnx_userIdconnatix.comPending30 daysHTTPdemdexAdobe Inc.Via a unique
ID that is used for semantic content analysis, the user's navigation on the
website is registered and linked to offline data from surveys and similar
registrations to display targeted ads.180 daysHTTPdpmAdobe Inc.Sets a unique ID
for the visitor, that allows third party advertisers to target the visitor with
relevant advertisement. This pairing service is provided by third party
advertisement hubs, which facilitates real-time bidding for advertisers.180
daysHTTPIDEGoogleUsed by Google DoubleClick to register and report the website
user's actions after viewing or clicking one of the advertiser's ads with the
purpose of measuring the efficacy of an ad and to present targeted ads to the
user.1 yearHTTPtest_cookieGoogleUsed to check if the user's browser supports
cookies.1 dayHTTPucidSAPRegisters a unique ID that identifies a returning user's
device. The ID is used for targeted ads.1 yearHTTPads/ga-audiencesGoogleUsed by
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websites.SessionPixelpagead/1p-conversion/1052523883/GooglePendingSessionPixelpagead/1p-conversion/622057748/GooglePendingSessionPixelpagead/1p-user-list/1052523883/GooglePendingSessionPixelrc::fGooglePendingPersistentHTMLio_token_#Power
ReviewsUsed by the website to detect any fraud and ensure brand safety
management on the website. 1 yearHTTPptIspot.tvUsed to track the visitor across
multiple devices including TV. This is done in order to re-target the visitor
through multiple channels. 2 yearsHTTP_kuid_SalesforceRegisters a unique ID that
identifies a returning user's device. The ID is used for targeted ads.180
daysHTTPbcookieLinkedInUsed by the social networking service, LinkedIn, for
tracking the use of embedded services.1 yearHTTPli_sugrLinkedInCollects data on
user behaviour and interaction in order to optimize the website and make
advertisement on the website more relevant. 3 monthsHTTPlidcLinkedInUsed by the
social networking service, LinkedIn, for tracking the use of embedded
services.180 daysHTTPUserMatchHistoryLinkedInUsed to track visitors on multiple
websites, in order to present relevant advertisement based on the visitor's
preferences. 30 daysHTTPmics_ltsMediarithmicsCollects information on user
preferences and/or interaction with web-campaign content - This is used on
CRM-campaign-platform used by website owners for promoting events or products.1
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interaction with web-campaign content - This is used on CRM-campaign-platform
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interaction with web-campaign content - This is used on CRM-campaign-platform
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ElectricPending1 yearHTTP_fbp Meta Platforms, Inc.Used by Facebook to deliver a
series of advertisement products such as real time bidding from third party
advertisers.3 monthsHTTP_gcl_auGoogleUsed by Google AdSense for experimenting
with advertisement efficiency across websites using their services. 3
monthsHTTP_gig_lt [x2]SAPCollects visitor data related to the user's visits to
the website, such as the number of visits, average time spent on the website and
what pages have been loaded, with the purpose of displaying targeted
ads.SessionHTTP_mkto_trkMarketoContains data on visitor behaviour and website
interaction. This is used in context with the email marketing service
Marketo.com, which allows the website to target visitors via email. 2
yearsHTTP_ttp [x2]TiktokUsed by the social networking service, TikTok, for
tracking the use of embedded services.1 yearHTTPt/v2XaxisCollects information on
user behaviour on multiple websites. This information is used in order to
optimize the relevance of advertisement on the
website.SessionPixelndatNinthdecimalUsed to track the visitor across multiple
devices including TV. This is done in order to re-target the visitor through
multiple channels. 1 yearHTTPw/1.0/sdOpenxRegisters data on visitors such as IP
addresses, geographical location and advertisement interaction. This information
is used optimize the advertisement on websites that make use of OpenX.net
services. SessionPixelKADUSERCOOKIEPubMaticRegisters a unique ID that identifies
the user's device during return visits across websites that use the same ad
network. The ID is used to allow targeted
ads.SessionHTTPKRTBCOOKIE_#PubMaticRegisters a unique ID that identifies the
user's device during return visits across websites that use the same ad network.
The ID is used to allow targeted ads.3 monthsHTTPKTPCACOOKIEPubMaticRegisters a
unique ID that identifies the user's device during return visits across websites
that use the same ad network. The ID is used to allow targeted
ads.SessionHTTPmcQuantcastCollects data on the user's visits to the website,
such as what pages have been loaded. The registered data is used for targeted
ads.13 monthsHTTPUID [x2]ScorecardResearch
FreewheelCollects information of the user and his/her movement, such as
timestamp for visits, most recently loaded pages and IP address. The data is
used by the marketing research network, Scorecard Research, to analyse traffic
patterns and carry out surveys to help their clients better understand the
customer's preferences.SessionHTTPSEUNCYSemasioRegisters a unique ID that
identifies the user's device for return visits.1 yearHTTPActivityInfo2SizmekUsed
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for advertisers.30 daysHTTPeyeblasterSizmekRegisters data on visitors from
multiple visits and on multiple websites. This information is used to measure
the efficiency of advertisement on websites. SessionHTTPu2SizmekCollects data
related to the user's navigation visits to webpages in order to assess the
efficacy of ads that are displayed on the website.30 daysHTTPaudienceSpotXUsed
to determine whether the video-ads have been displayed correctly on the website
- This is done to make video-ads more effective and ensure that the visitor is
not shown the same ads more times than intended. The cookie also detects whether
the visitor has any Do Not Track preferences.28
daysHTTPuid-bp-#FreewheelPending14 daysHTTPi/adsct [x2]Twitter Inc.The cookie is
used by Twitter.com in order to determine the number of visitors accessing the
website through Twitter advertisement content. SessionPixelmuc_adsTwitter
Inc.Collects data on user behaviour and interaction in order to optimize the
website and make advertisement on the website more relevant. 2
yearsHTTPtv_UIAMTelariaPending2 yearsHTTPtvidTelariaPresents the user with
relevant content and advertisement. The service is provided by third-party
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on the website. The cookie also stores which products the user finds
interesting, which is used for marketing purposes. SessionHTMLgig_canarySAPUsed
to identify the visitor across visits and devices. This allows the website to
present the visitor with relevant advertisement - The service is provided by
third party advertisement hubs, which facilitate real-time bidding for
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visits and devices. This allows the website to present the visitor with relevant
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SessionHTTPps-uidcdn.pricespider.comUsed to track visitors on multiple websites,
in order to present relevant advertisement based on the visitor's preferences.
SessionHTTPA1YahooPending1 yearHTTPA1SYahooPendingSessionHTTPA3YahooCollects
information on user behaviour on multiple websites. This information is used in
order to optimize the relevance of advertisement on the website.1
yearHTTPBYahooCollects anonymous data related to the user's website visits, such
as the number of visits, average time spent on the website and what pages have
been loaded. The registered data is used to categorise the users' interest and
demographical profiles with the purpose of customising the website content
depending on the visitor.1 yearHTTPLAST_RESULT_ENTRY_KEYYouTubeUsed to track
user’s interaction with embedded
content.SessionHTTPLogsDatabaseV2:V#||LogsRequestsStoreYouTubePendingPersistentIDBnextIdYouTubeUsed
to track user’s interaction with embedded
content.SessionHTTPnWC1Uzs7EIYouTubePendingSessionHTMLremote_sidYouTubeNecessary
for the implementation and functionality of YouTube video-content on the
website. SessionHTTPrequestsYouTubeUsed to track user’s interaction with
embedded
content.SessionHTTPServiceWorkerLogsDatabase#SWHealthLogYouTubeNecessary for the
implementation and functionality of YouTube video-content on the website.
PersistentIDBTESTCOOKIESENABLEDYouTubeUsed to track user’s interaction with
embedded content.1 dayHTTPVISITOR_INFO1_LIVEYouTubeTries to estimate the users'
bandwidth on pages with integrated YouTube videos.180
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seen.PersistentHTMLytidb::LAST_RESULT_ENTRY_KEYYouTubeStores the user's video
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videoSessionHTMLyt-remote-session-appYouTubeStores the user's video player
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videoSessionHTMLyt-remote-session-nameYouTubeStores the user's video player
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* 5 Benefits of a Switch to Wire Welding Processes in Pipe Welding
5 BENEFITS OF A SWITCH TO WIRE WELDING PROCESSES IN PIPE WELDING
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Learn how to optimize open root pipe welding with a switch to advanced wire
welding processes in shop and field applications.
ROOT PASS WELDING CHANGE
Change can be hard, but leaders in the pipe welding industry are upping their
game by changing from the status quo.
Meeting stringent quality requirements and demanding project timelines are
critical in pipe welding, both in the field and the shop. Having the
capabilities for advanced welding processes when customers call for them means
contractors can capitalize on those opportunities and bid on more jobs.
Approximately 80% of the costs associated with welding are related to labor.
Giving welders technology and equipment that improves their productivity can
save significant time and money.
Here are five benefits a switch to the Regulated Metal Deposition (RMD®) process
for open root pipe welding in shop and field applications can deliver.
5 BENEFITS OF CONVERTING TO WIRE WELDING
1. Faster process changeover
Using advanced wire processes like RMD (a modified short-circuit MIG
process) and pulsed MIG welding allows for simple process changeover between
weld passes with the push of a button.
This greatly reducing switch-over time compared to using TIG and stick
welding, which requires changing polarity between each process switch. With
PipeWorx 400 and XMT® 350 FieldPro™ with Polarity Reversing systems,
operators can change polarity with the push of a button — without moving the
electrical connection. In addition, RMD and pulsed MIG can provide a one
wire, one gas solution that reduces time spent on changeover.
In the shop, a welding system with a dual feeder option allows flexibility
to set up each side with any gas or filler metal combination required. This
delivers even more time savings in setup and switch over. Operators can just
pick up the desired welding gun and weld.
2. Improved productivity
RMD and advanced wire processes are much more productive than TIG and stick
welding for several reasons.
The wire-fed processes offer travel speeds that are three to four times
those of TIG or stick welding. Wire processes are typically easier for new
welders to learn than TIG and stick welding, which saves time in training.
In the PipeWorx 400 system and the ArcReach® Smart Feeder, RMD is also
fine-tuned for open root pipe and vessel welding. This makes the process
more efficient for producing code-quality welds.
Pipe fabricator Dixie Mechanical doubled welding productivity — completing
twice as many welds in the same amount of time — with a process switch. The
company had been welding stainless steel pipe with a TIG root pass and argon
back purge followed by flux-cored fill and cap passes. They switched to an
RMD root pass and eliminated the time-consuming and costly back purge.
Kiewit Power Constructors also increased productivity when they switched to
RMD and flux-cored welding for several power plant projects. In some
instances where Kiewit previously TIG welded the root pass for P11 and P91
pipe, they used RMD without a purge. For the remaining passes, they used
flux-cored welding instead of stick.
3. Optimized arc performance
The RMD process is engineered with a high-quality arc specifically tailored
for open root/joint pipe and vessel welding.
Early prediction of the short clearing enables the power source to quickly
reduce the available current. This minimizes the excessive arc force on the
puddle and results in a calm, controllable puddle.
The smooth arc and bead profile wets out nicely — helping welders of all
skill levels produce high-quality welds.
RMD and advanced wire processes aren’t limited to shop welding applications,
either. With the ArcReach Smart Feeder, you get consistent arc performance
on the jobsite for multiple weld processes — even when weld cables are
hundreds of feet long.
4. Eliminate back purge
Using RMD instead of TIG for the root pass on stainless steel and chrome
pipe welds may allow operations to eliminate the back-purge process. Back
purging provides gas shielding on the back side of the joint while welding,
but it adds significant time and money to the process.
It can require 20 to 30 minutes each time, depending on pipe size, to set up
the argon shielding gas and tape the pipe ends for purging. In addition, the
argon gas used for back purging adds to consumable costs. Back purging can
also introduce safety hazards to operators who can be overcome by the argon
gas and suffer inert gas asphyxia. Eliminating back purge saves time and
money and reduces the risks involved with the process.
With RMD, welders can more easily control the weld puddle, welding speeds
and heat input. A lower heat input allows the weld puddle to freeze faster.
All of these factors combine to result in a less turbulent weld puddle and
smoother shielding gas flow. This allows the gas to push through the open
root and protect the weld's back side from sugaring, or contamination.
Because the puddle freezes so quickly in the RMD process, such gas coverage
is only needed for a short time — eliminating the need for back purging.
5. Train new welders faster
As the industry faces a continued shortage of skilled welders, contractors
are looking for ways to train new welders faster. This may be especially
critical on large plant construction projects that span two to three years
and require dozens of full-time welders.
Compared to stick and TIG welding, wire-fed processes like RMD are generally
easier to learn and use, reducing training time.
You can avoid the welding problems that threaten construction schedules and
drive up costs.
LEARN MORE
SAVE TIME AND MONEY WITH A WELDING SWITCH
A welding process change can deliver big rewards for pipe welding, both in the
shop and in the field. An advanced wire process like RMD can help operations
improve productivity, train welders faster and produce high-quality welds —
saving time and money in the long run. Want to learn more about RMD and how to
use it? Learn more here.
Stay up to date on what's happening in pipe welding. Both educational and
entertaining - hear exciting dialogues and various perspectives that are full of
wide ranging and yet focused conversations from elite professionals in the pipe
welding industry.
LISTEN HERE
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Published: December 9, 2020
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