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Story title
List of Story articles
Jason Becker served as a Sergeant in the U.S. Marine Corps before becoming a welding educator and Arc Junkies Podcast host.
Story title
List of Story articles
Jason Becker served as a Sergeant in the U.S. Marine Corps before becoming a welding educator and Arc Junkies Podcast host.
January 2021
January 2021
trend publishing metals group  Volume 18 Number 01
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spotlight: Veterans
Veterans have valuable resources available after leaving active service that can lead to a lifelong career in the metal fabrication sector
FFJournal logo
spotlight: Veterans
Veterans have valuable resources available after leaving active service that can lead to a lifelong career in the metal fabrication sector
military personnel posing for a picture
Cover photo: Steven Sobel, Valencia College
laser technology
press brake
metal bending
deburring
waterjet machine
features
laser technology
Automation and high-speed cutting coupled with web-based demonstrations help fabricators thrive despite pandemic
Press Brake/ Tooling
Versatile tooling technology saves time, boosts output and allows an operator to perform multiple jobs with a single setup
bending/ folding
Manufacturers turn to precision folding technology to raise throughput, enhance part quality and take the load off operators
deburring/ finishing
Metal finishing is a tedious process that requires a balance of time and precision
waterjet
A capital investment pays off for a new shop owner
features
laser technology
Laser Technology
Automation and high-speed cutting coupled with web-based demonstrations help fabricators thrive despite pandemic
press brake
Press Brake/ Tooling
Versatile tooling technology saves time, boosts output and allows an operator to perform multiple jobs with a single setup
precision tooling
bending/ folding
Manufacturers turn to precision folding technology to raise throughput, enhance part quality and take the load off operators
deburring
deburring/ finishing
Metal finishing is a tedious process that requires a balance of time and precision
waterjet machine
waterjet
A capital investment pays off for a new shop owner
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motorcycle
/customfabricator
cut pipe
/sawing
man using a buzzsaw
/pov
Online
Features
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customfabricator
Custom shop Eastern Spirit Garage took a 1993 BMW R80 ESG 649 that was missing a number of key components and turned it into something radical—three bikes in one
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sawing
Determining the right tooth count, pitch and grind make all the difference
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pov
In a sector rocked by global adversity, small is now big, and short could go a long way
at sign
multiple people welding
Facebook
A college friendship blossoms into sculptures that will last centuries
Photo: Art Research Enterprises
welder
Instagram
#welding #dayattheoffice #Texas #fabshop #hoods
Photo: @jkwelding
men welding
Twitter
Maine community college welding program provides immigrants with new skills
Learn more
@PressHerald
Photo: Southern Maine Community College
Gretchen Salois Portrait

From the Editor

GRETCHEN SALOIS, SENIOR EDITOR
Fresh start
I

t’s a new year and the fact that 2020 wasn’t a hallmark time for so many people isn’t lost on anyone. New beginnings prompt us to think of possible resolutions or plans for the upcoming months. If 2020 taught us anything, it’s that we can lay all the groundwork for plans that are ultimately at the mercy of circumstances we can’t predict or control.

We can, however, reflect upon what we have learned and make informed decisions about how to approach the future, no matter the unknown. Although the economy has faltered and millions are out of work, the fabrication sector is a welcome bright spot. Countless fab shops are adapting to shifting demand, as drops and surges in the marketplace continue to be felt—and likely will be well into the new year.

Guest Editorial
By Jeff Kirchner, high performance alloys
COVID-19 and 2020
Flexibility contributes to a growth mindset during uncertain times
A

s an essential business, in a right-to-work state, High Performance Alloys has been blessed to maintain its open status. One of the ways our company prepared for a downturn was to apply and receive assistance via the federal government’s Paycheck Protection Program (PPP). The PPP was designed to help companies survive a three-month shutdown, covering salaries and expenses, with 2019 numbers as the guide to those amounts.

The Hot Sheet
technology
(L) AIMS Vice President Mark Gearding and (R) President Dave Delph work with new Summit.
Game Changer
New CMM Gives Job Shops MultiSensor 5-Axis Inspection

Job shops are being asked to process and measure more complex parts amid stricter supply chain quality standards. Demand for 100 percent parts inspection for new product lines is also growing. AIMS Metrology, an OEM for coordinate measuring machines, has designed and introduced the new Summit 10.10.10 to put REVO-2 5-axis dynamic scanning and multisensor surface finish measurement [including video probing] into the hands of the operator. Engineered with 1 meter cubed capacity, the Summit provides high-volume large parts inspection. It can be automated with a robot load/unload system or pass through process with a conveyor.

SPOTLIGHT:

VETERANS

SPOTLIGHT:

VETERANS

BY GRETCHEN SALOIS, SENIOR EDITOR
A free education while earning a paycheck and learning a trade is becoming more appealing than a life of student debt.
Mike Hazard, UA VIP
Next
Steps
Veterans have valuable resources available after leaving active service that can lead to a lifelong career in the metal fabrication sector
A

fter serving for years in the military, the shift from active duty to civilian life can be daunting. Helpful programs exist during and after life in the military to help service members consider a career in the metal fabrication sector. FFJournal learns from those teaching, studying and organizing efforts to connect veterans with potential long-term career paths.

One of the biggest challenges facing the fabrication industry is finding qualified talent. “People coming out of the military make excellent candidates,” says Michael Harris, program administrator at the International Training Institute SMART workers program. “They’re used to working in a team environment, are dependable and take responsibility.”

Next
Steps
A free education while earning a paycheck and learning a trade is becoming more appealing than a life of student debt.
Mike Hazard, UA VIP
Veterans have valuable resources available after leaving active service that can lead to a lifelong career in the metal fabrication sector
A

fter serving for years in the military, the shift from active duty to civilian life can be daunting. Helpful programs exist during and after life in the military to help service members consider a career in the metal fabrication sector. FFJournal learns from those teaching, studying and organizing efforts to connect veterans with potential long-term career paths.

One of the biggest challenges facing the fabrication industry is finding qualified talent. “People coming out of the military make excellent candidates,” says Michael Harris, program administrator at the International Training Institute SMART workers program. “They’re used to working in a team environment, are dependable and take responsibility.”

Laser Technology
By Lynn Stanley, senior editor
Active Speed Control allows the TruLaser 5030 fiber laser to automatically increase feed rates while adapting to material changes and maintaining part quality.
Getting ahead
Automation and high-speed cutting coupled with web-based demonstrations help fabricators thrive despite pandemic
I

n 1849, thousands of people faced boom or bust when they left their homes and jobs to pan for precious metal in the California Gold Rush. These days, depending on the industry, manufacturers are facing a boom or bust cycle of a different sort. “Due to COVID-19, markets such as food equipment are seeing declines in products like stainless cookware,” says Brett Thompson, sales engineer for Trumpf Inc.

Press Brake/Tooling
By Lynn Stanley, senior editor
AMADA Fixed Height tooling allows the operator to combine different profiles in one common setup.
Breaking bottlenecks
Versatile tooling technology saves time, boosts output and allows an operator to perform multiple jobs with a single setup
M

odern products and the technology required to make them have changed the face of supply chains across the U.S. An era of specialists has emerged to perform work that used to belong exclusively to vertically integrated manufacturers like Ford or General Motors. For job shops with bending operations, it means managing multiplex parts, shrinking lot sizes and shorter delivery windows.

Bending/Folding
By Lynn Stanley, senior editor

RTT Engineered Solutions found the Schröder PowerBend Industrial 4m metal folding machine increased part quality and operator safety.

SUSTAINABLE
PROCESSING
Manufacturers turn to precision folding technology to raise throughput, enhance part quality and take the load off operators
B

ending is still a nightmare for most job shops,” says MetalForming Inc. Executive Vice President David Prokop. “Sustainability is a huge issue. An aging workforce coupled with an evaporating labor pool means a manually intensive process is no longer feasible. Instead, you want an ergonomically sound machine that eliminates the need for operators to manhandle parts. Repetitive motion injuries and worker safety also point employers to a process that can create sustainable, controllable output.”

Deburring/Finishing
BY CEDRIK ROCHON & CHARLES GYRION, WALTER SURFACE TECHNOLOGIES
BLENDING FASTER
& SMARTER
Metal finishing is a tedious process that requires a balance of time and precision
The Enduro-Flex Turbo removes like a 36 grit but leaves a 60 grit finish, saving finishing steps.
M

ultiple industries are recognizing the importance of workers being able to do their jobs with less fatigue, more comfort and greater efficiency. Working better and smarter requires the right tools and processes in order to repeatedly achieve the desired finish—especially when working with stainless steel. The abrasive used for the job, the grit type, grain and operator technique all affect surface finish.

An equipment manufacturer in Wisconsin was experiencing excessive labor and cost waste, a common issue in the metalworking industry. The grinding wheel needed to be dressed to maintain its removal rate and grinding angle. As a result, the operator had to manually discard the wheels prematurely, resulting in higher production costs and longer output times.

“Prior to introducing the Enduro-Flex Turbo, we had a flap disc, but not a good one,” says the plant supervisor. “It worked ok, but we didn’t know what we were missing.”

Waterjet
By gretchen salois, senior editor
A steady increase for precisely cut steps and rails for ladders compelled T.R. Welding & Fabrication to invest in waterjet technology.
The Plan Ahead
A capital investment pays off for a new shop owner
I

t’s a nightmare scenario: you sign the contract for a new waterjet cutter and the following week the country is shut down due to a pandemic. “I signed up for my new machine right before COVID-19 hit and everything went into lockdown,” recalls Tom Racicot, owner of T.R. Welding & Fabrication LLC. His fear didn’t linger, however. Within a week he was back to focusing on the survival of his business with the help of his new machine.

Racicot is used to making risky decisions. After working full-time for 15 years for another employer, he took a leap of faith and started T.R. Welding & Fabrication. The decision felt right when he began to accept requests from customers before he had a welding torch to do the work.
Toolbox
Inverter for TIG and stick welding
Welding
Inverter for TIG and stick welding
Weighing only 21.4 pounds, the Striker 160 welding inverter is a small, compact, dual voltage (115 volt or 230 volt) single-phase inverter unit with digital readouts that automatically identify the power grid voltage and operate accordingly. The Striker 160 machine features power factor corrector (PFC), which increases power efficiency, reduces input power requirements and stabilizes the welding current, maximizing efficiency on extension cords and generators. A voltage reduction device (VDR) reduces voltage across the outputs when idling. Works with a wide range of input voltages, from 98 volts to 265 volts, the Striker 160 is ideal for use with generators.

Weldcote, Kings Mountain, North Carolina, 704/739-4115, weldcotemetals.com.

Custom Fabricator
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
Lulu
“Engine” is the operative prefix in the word “engineer,” so it follows that when retired engineer Paul Kalenian designed and built an automotive chassis, the focus would be on the engine. In this case, the engine is a GM LTG crate motor/transaxle selected for its power density. At 295 HP, the DOHC, direct injection, 6-speed 2L turbo 4 weighs in at just 265 lbs. Lulu’s chassis, like an airplane, is an all-aluminum monocoque/bulkhead design that was waterjet cut from 6061 aluminum and heliarc welded into a torsionally stiff independent coil over suspension. The solidly mounted motor/transaxle is a structural component of this mid-rear-wheel drive layout. Raising the boost via ECU reprogramming to 25 psi provides 325 hp, propelling the 1,530 lb. (wet) chassis from 0 to 60 mph in about 3 seconds. Lulu cruises with very responsive handling, due to 34 in. overall height, low center of gravity and 76 in. width with a 102 in. wheel base. “Lulu” is fully street legal and in her first year has been driven over 4,000 mostly reliable miles. “Lu2” is currently in design-build with a BMW K1600B MC engine and a projected weight of 850 lbs.
Photo: Paul Kalenian
Paul Kalenian's car, "Lulu"
Lulu
“Engine” is the operative prefix in the word “engineer,” so it follows that when retired engineer Paul Kalenian designed and built an automotive chassis, the focus would be on the engine. In this case, the engine is a GM LTG crate motor/transaxle selected for its power density. At 295 HP, the DOHC, direct injection, 6-speed 2L turbo 4 weighs in at just 265 lbs. Lulu’s chassis, like an airplane, is an all-aluminum monocoque/bulkhead design that was waterjet cut from 6061 aluminum and heliarc welded into a torsionally stiff independent coil over suspension. The solidly mounted motor/transaxle is a structural component of this mid-rear-wheel drive layout. Raising the boost via ECU reprogramming to 25 psi provides 325 hp, propelling the 1,530 lb. (wet) chassis from 0 to 60 mph in about 3 seconds. Lulu cruises with very responsive handling, due to 34 in. overall height, low center of gravity and 76 in. width with a 102 in. wheel base. “Lulu” is fully street legal and in her first year has been driven over 4,000 mostly reliable miles. “Lu2” is currently in design-build with a BMW K1600B MC engine and a projected weight of 850 lbs.
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
Photo: Paul Kalenian
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President/Publisher
Editor-in-Chief

Michael D’Alexander

Editorial
Senior Editor

Lynn Stanley

Senior Editor

Gretchen Salois

Senior Contributing Editor

J. Neiland Pennington

Contributing Editor

Lauren Duensing

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FFJOURNAL® (ISSN 1551-1006) January 2021 (Vol. 18, No. 1) 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 FFJOURNAL® c/o Creative Data Services, Inc., 440 Quadrangle Drive Suite E, Bolingbrook, IL 60440. Printed in the USA.
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