Ironworkers
Welding
Question and Answers
AWS
FMA PMA
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The American Welding Society, Fabricators & Manufacturers Assn. Int’l and the Precision Metalforming Assn. discuss the tools they are using to help the industry survive and thrive
April 2022
April 2022
trend publishing metals group  Volume 19 Number 04
April 2022
trend publishing metals group  Volume 19 Number 04
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The magazine for today’s metal
fabricating & forming technologies
special report
As strong demand faces off against production challenges, three industry leaders have the vision and the tools to help manufacturers thrive
features
Cookin’ With Gas
laser technology
Coil-fed fiber laser technology automates cutting process, reduces inventory and scrap, and improves work environment
Cookin’ With Gas
High Volume
Here Comes The Sun
A Fine Balance
Automation Implementation
welding
Automation fills labor gap, raises throughput and helps fabricator make parts more efficiently in fast-paced market
ironworkers
Fabricator boosts capacity with a Sunrise CNC ironworker
deburring/finishing
Choosing the correct abrasive helps users meet requirements efficiently
sawing
A service center transitions to automatic equipment, reducing downtime
High Volume
welding
Automation fills labor gap, raises throughput and helps fabricator make parts more efficiently in fast-paced market
Here Comes The Sun
ironworkers
Fabricator boosts capacity with a Sunrise CNC ironworker
A Fine Balance
deburring/finishing
Choosing the correct abrasive helps users meet requirements efficiently
Automation Implementation
sawing
A service center transitions to automatic equipment, reducing downtime
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Kim Olson, manager of technical initiatives, Construction Solutions, Nucor Corp., discusses Nucor’s current and future commitments to sustainability
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From the Editor

lynn stanley

Community

W

e’ve all heard the African proverb, “It takes a village to raise a child.” The idiom has been adapted over time to mean that “many people must cooperate to achieve a goal.” That was certainly the case when my Paso Fino gelding was diagnosed with Cushings disease and insulin resistance in 2019. A large animal veterinarian, an internal medicine/nutritionist veterinarian, an equine endocrinologist, an equine chiropractor, and a farrier and hoof specialist participate in managing his condition.

There are about 126,138 veterinarians and 28,000 farriers in the U.S. Competition for admission to veterinary college is stiff, with the acceptance rate between 10 and 15 percent. Qualified farriers are also in high demand. Like metalforming, farriery is part art, skill, science and craftsmanship. Working with one’s competitors can seem counterintuitive. In my case, these competitors chose to collaborate—extending professional courtesy toward one another to form and implement a plan that effectively manages my horse’s condition and allows him to thrive.

Guest Editorial
BY PETER NACHTWEY, PRESIDENT, DELTA COMPUTER SYSTEMS
TAKE CONTROL
Improve machine productivity, lower life-cycle costs with motion control upgrades
M

anufacturers are bombarded with challenges daily: supply chain disruptions for both raw materials and required components, finding and retaining a qualified workforce, and pressure for increased productivity at higher profitability. These economic conditions usually mean delaying new equipment investment to save money. Retrofitting existing equipment with contemporary electronic controls can significantly increase performance while preserving the existing mechanical and power components that may have many decades of useful life ahead.

Forward motion
Electronic machine control and automation technology have reaped benefits from the boom in consumer electronics. Motion control problems were theoretically solved as far back as the 1940s and 1950s, but the solutions weren’t useful in practice because there wasn’t a way to calculate the equations fast enough to provide results that could be used to guide machines, especially those powered by hydraulics or pneumatics.
Training & Education
BY AWS STAFF

Jason Becker, welding educator and podcast host, spearheaded a project-based learning program at Valencia College.

Jason Becker using audio equipment
Jason Becker, welding educator and podcast host, spearheaded a project-based learning program at Valencia College.
Job Ready
Industry organization helps Valencia College accredit its welding program, opening doors for higher enrollment and better equipment
P

roject-based learning can be broadly described as real-world experience in an educational setting. Teaching welding with a project-based model requires a unique combination of not only welding skill and knowledge of tools used in the industry but also of blueprint reading, troubleshooting, budgeting, scheduling, and team- and relationship-building—not to mention providing students with industry exposure to field work.

Jason Becker, welding educator at Valencia College, Orlando, Florida, and host of the Arc Junkies podcast, knows firsthand what this looks like in real time. After attending an Advanced Educators’ Workshop in 2017, Becker started a project-based learning program at Valencia College. He started small but has since raised the bar with additional and more complex projects relevant to various industry applications.

Hot Sheet
close up of a robotic arm
WELDING
Cobots have the potential to eliminate complex programming and create a greater degree of flexibility.

Robotics

Job shops should weigh the pros and cons of automated welding before taking the plunge

National Welding Month (April) was established in 1996 to recognize the industry and its tradespeople. From railcars, electric vehicles, buildings and bridges to truck racks, computers, cell phones and common household items, welding contributes to nearly 70 percent of products manufactured in the U.S. The Bureau of Labor Statistics forecasts a 3 percent uptick in job growth for welders over the next decade. Yet the American Welding Society (AWS) predicts a shortage of 300,000 welders by 2024, citing the large number of baby boomers retiring and negative perceptions about the career.

Companies are choosing robotic automation to help bridge the gap. The technology has progressed since the first spot welding robot was introduced in 1962. Today robotic welding is primarily used for high-volume, repetitive processes.

One of FMA’s summer camps—Girls Adventuring in Design, Engineering and Technology (GADgET)—is held at host schools like Northcentral Technical College, Wisconsin.

special report
By Lynn Stanley, Senior Editor
Safety net
As strong demand faces off against production challenges, three industry leaders have the vision and the tools to help manufacturers thrive
W

hen the sequel “Harry Potter and the Chamber of Secrets” film opened in 2002, fans flocked to theaters around the world to see the “boy who lived” board the Hogwarts Express train at King’s Cross Station, Platform Nine and Three-Quarters. A mysterious elf warns Harry to expect trouble, but the problems he encounters in the form of a cursed diary, a giant basilisk and the “dark lord” prove almost insuperable. That is, until help arrives from an unexpected quarter. Hogwarts Headmaster Albus Dumbledore explains: “You will find that help will always be given at Hogwarts to those who ask for it. The school itself isn’t sentient, it’s the people inside who will always be there to help.”

Special report
By Lynn Stanley, Senior Editor

One of FMA’s summer camps—Girls Adventuring in Design, Engineering and Technology (GADgET)—is held at host schools like Northcentral Technical College, Wisconsin.

Safety net
As strong demand faces off against production challenges, three industry leaders have the vision and the tools to help manufacturers thrive
W

hen the sequel “Harry Potter and the Chamber of Secrets” film opened in 2002, fans flocked to theaters around the world to see the “boy who lived” board the Hogwarts Express train at King’s Cross Station, Platform Nine and Three-Quarters. A mysterious elf warns Harry to expect trouble, but the problems he encounters in the form of a cursed diary, a giant basilisk and the “dark lord” prove almost insuperable. That is, until help arrives from an unexpected quarter. Hogwarts Headmaster Albus Dumbledore explains: “You will find that help will always be given at Hogwarts to those who ask for it. The school itself isn’t sentient, it’s the people inside who will always be there to help.”

Laser Technology

By Lynn Stanley, senior editor
Dallan coil-fed LXN 1500 fiber laser
(L) The Dallan coil-fed LXN 1500 fiber laser’s vision repositioning system eliminates seconds from the process and improves cut quality. The machine helps CaptiveAire reduce inventory for hard-to-source stainless steel.
Cookin’ with gas

Coil-fed fiber laser technology automates cutting process, reduces inventory and scrap, and improves work environment

T

he advertising slogan, “Now we’re cooking with gas,” originated in the 1930s and was adopted as a catchphrase by comedian Bob Hope for his radio and TV performances. Almost a century later, the motto has morphed into an American idiom for positive progress or achievement. It’s a definition that fits CaptiveAire Systems. The Raleigh, North Carolina-based company is the nation’s leading manufacturer of commercial kitchen ventilation systems and turnkey solutions for fans, heaters, ductwork and HVAC equipment.

The company launched its small, one-room operation in 1976. By 2016, CaptiveAire’s sales had surpassed $400 million. Today with more than 1,500 employees, the manufacturer has 90 sales offices in the U.S. and Canada, and six plants in North Carolina, Iowa, Oklahoma, California, Pennsylvania and Florida. CaptiveAire serves restaurants, national chains, and other public and private institutions. Product fabrication for CaptiveAire’s integrated kitchen ventilation packages includes HVAC, hoods, exhaust fans, electrical controls, direct-fired heaters, grease duct systems, fire suppression systems, grease filters and utility distribution systems. The company has built its business on quality products and fast, reliable lead times.

Welding
BY LYNN STANLEY, SENIOR EDITOR
automation machine

High
Volume

Automation fills labor gap, raises throughput and helps fabricator make parts more efficiently in fast-paced market
A

ccording to the 2021 North American Camping Report, there are 86.1 million households in the U.S. that have active campers. Tents remain a popular choice, but the number of households that own recreational vehicles grew by 2.6 million. More than 80 percent of campers changed their habits in 2020, choosing RVs for travel safety. With RV interest and ownership at a record high, data from the Ipsos Group showed that 46 million Americans plan to take an RV trip in the next 12 months.

Elkhart, Indiana, is the RV capital of the world, with more than 80 percent of global RV production based throughout the region. Just 15 minutes away, along IN-120 W, Bristol is home to JEC Steel Co.

“The RV market has been on an upward trend,” says Owner Jeremy Seniff. “When COVID-19 hit, the area we live in became a boomtown. RV production jumped from 480,000 units to 630,000 units. The supply chain has been stressed and strained, but I don’t see that as a bad thing. For us, it was a huge part of our growth.”
ironworkers
By Alan Richter, contributing editor
Sunrise IW110SD
Here Comes the Sun
Fabricator boosts capacity with a Sunrise CNC ironworker
A

llfasteners Inc. began in Australia as a supplier of construction fasteners and concrete anchors. The company retained those product offerings while expanding its business about eight years ago to include structural steel fabrication and production of cellular tower parts and a tower safety climb system.

In addition, the company grew its footprint over the years and now has four locations in Australia and four in the U.S., with a manufacturing facility in Medina, Ohio, and three other U.S. locations for sales and warehousing.

As a way to get started in structural steel fabrication, Allfasteners purchased a manual ironworker, says Tony Carmichael, operations manager for Allfasteners in Medina. But the company eventually realized the limitations of the manual machine. “We found that we did not have enough capacity with that machine.”

deburring/finishing
By Frank Prenda, vice president, sales and marketing, Gemtex Abrasives
A Fine Balance
A Fine Balance
Choosing the correct abrasive helps users meet requirements efficiently
S

urface conditioning products are part of an ever-expanding category of nonwoven abrasives. The global nonwoven abrasives market hit $18.47 billion in sales during 2021 and is projected to increase at a compound annual growth rate of nearly 6.2 percent, reaching $24.99 billion by 2026. These products, in various shapes and sizes, are used to blend, deburr, grain and polish metals when specific surface finishes are required.

Due to the versatility of this category and requests from customers, Gemtex has added three new grades to expand its Brite-Prep surface finishing line. These grades help to reduce the need to use coated abrasive products, which could possibly scratch or damage metal surfaces. Extra Coarse, Extra Coarse High Density and Medium High Density have been added to provide longer life, a more aggressive cut and more rigidity within the surface conditioning category.

sawing
By Alan Richter, Contributing Editor
Automation
Implementation
A service center transitions to automatic equipment, reducing downtime
The WF130HA-DC-C band saw cuts
The WF130HA-DC-C band saw cuts a bundle of material at West Memphis Steel.
W

ith its sawing department operating around the clock five days a week plus an eight- to 10-hour shift on Saturdays, West Memphis Steel Corp. found that a manual band saw doesn’t cut it anymore and needs all its machines to be automatic moving forward, says Josh Stewart, the company’s maintenance manager. Automatic band saws enable a faster cutting process while maintaining part accuracy, even for complex sawing operations, compared with manual and semiautomatic models. In addition, jobs can be combined into a program and run in the order the operator selects.

“The very first machine we purchased was a manual machine. Since then, we’ve seen that everything needs to be automated. It reduces downtime due to errors with cuts,” Stewart says about an automatic band saw. “Once you set the program, the saw works really well.”

The manual band saw, installed in 2015, is a WF130 from Pryor, Oklahoma-based HE&M Inc. Stewart says WMS still uses the saw but is looking to replace it this year as the Arkansas-based service center updates and expands its equipment lineup. WMS also has four VT140 automatic band saws from HE&M and plans to purchase more automatic models. “We will have a total of nine HE&M saws by the end of the year.”

The WF130HA-DC-C band saw cuts a bundle of material at West Memphis Steel.
Toolbox
AMADA’s REGIUS Series machine front view
AMADA’s REGIUS Series side view
LASER TECHNOLOGY
Fiber lasers offer versatility
AMADA’s REGIUS Series ensures continuous ultra-high-speed processing by leveraging the combined assets of a 3-axis linear drive system and numerous autonomous features. The linear drive reaches traverse speeds of 13,300 in. per minute. REGIUS reduces the time required to process complex nests by 15 percent compared to previous models. The BREVIS 1212 AJ features reliable high-speed laser cutting, easy material loading and a flexible Z-axis to ensure efficient cutting of assembled or pre-formed parts. This system cost effectively handles all work from prototyping to full-scale production.
AMADA AMERICA INC., Buena Park, California, 714/739-2111, amada.com/america.
Custom Fabricator
STILRIDE SUS1

Giving the ancient Japanese art of folding paper a modern update, STILRIDE has developed industrial origami. The Swedish startup pioneered the process called StilFold to create its SUS1 electric scooter. The method uses robotic arms to fold pieces of recycled stainless steel into a bike chassis. As a result, manufacturing requires significantly fewer components while reducing labor production costs for a more sustainable product. Although still in production, prototypes of the scooter have reached a top speed of up to 60 mph and a max range of 75 miles. The Stilride SUS1 electric scooter is expected to hit European markets in fall 2022.

Learn more about this and other Custom Fabricators at ffjournal.net/customfabricator.
Photo: Stilride
STILRIDE SUS1

Giving the ancient Japanese art of folding paper a modern update, STILRIDE has developed industrial origami. The Swedish startup pioneered the process called StilFold to create its SUS1 electric scooter. The method uses robotic arms to fold pieces of recycled stainless steel into a bike chassis. As a result, manufacturing requires significantly fewer components while reducing labor production costs for a more sustainable product. Although still in production, prototypes of the scooter have reached a top speed of up to 60 mph and a max range of 75 miles. The Stilride SUS1 electric scooter is expected to hit European markets in fall 2022.

Learn more about this and other Custom Fabricators at ffjournal.net/customfabricator.
Photo: Stilride
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Alan Richter

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FFJournal® (ISSN 1551-1006) April 2022 (Vol. 19, No. 04) is a registered trademark of Trend Publishing Inc. FFJournal® is published 11 times by Trend Publishing Inc., with its publishing office located at 123 W. Madison St., Suite 950, Chicago, Illinois 60602, 312/654-2300; fax 312/654-2323. Michael D’Alexander, President, Trend Publishing Inc. Copyright 2020 Trend Publishing Inc. All rights reserved under the United States, International and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means—mechanical, photocopying, electronic recording or otherwise—without the prior written permission of Trend Publishing Inc. Opinions expressed in articles are those of the authors and do not necessarily reflect those of Trend Publishing Inc. Published free of charge for those who qualify. It is mailed at no cost to these qualified readers in the U.S., Canada and U.S. possessions. Single copies $14. Paid subscriptions in the U.S., $120/year. Canada, $140/year. Foreign subscriptions, $175/year surface mail and $255/year air mail. For subscription information, go to www.ffjournal.net or call 312-654-2300. Periodicals postage paid at Chicago and additional mailing offices. Postmaster: Send address changes to: Omeda – FFJournal – 4 Overlook Pt., Ste. A25E, Lincolnshire, IL 60069. Printed in the USA.
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