D/F Machine Specialties will showcase several new heavy-duty automated and robotic MIG & TIG welding products at the 2011FABTECH International/AWS Welding Show at McCormick Place in Chicago, IL, November 14-17. Look for D/F in booth 6466.

Here is your most recent issue of High Current News. It's packed full of information to keep you updated with the latest MIG & TIG news, product information and updates from D/F MACHINE SPECIALTIES.

D/F is a world leader in the design, development, and manufacture of American made "MIG" (GMAW) & "TIG" (GTAW) torches for robotic and welding automation equipment, welding products, consumables and accessories.

Let us take this time to wish you a happy and safe holiday on this upcoming Independence Day weekend!

Strategies for Quality Robotic Welding

Robotic WeldingWelding is an art as well as a science. Theory can be well learned in a classroom, but the subtleties can only be learned with hands-on experience. For this reason, replacing a human with a robot requires that robot to maintain great quality and precision. This should be further guaranteed by assigning an experienced welder to operate and troubleshoot the new welding machine.

While the robotic-cell technician maintains the welding setup and process, many variables exist that should be considered when creating or adjusting parameters. Further, the results of the changes made to the weld program should be monitored and analyzed to adjust the program to try to attain the ideal weld setup.

Application variables such as material type, joint design, fit-up and position are analyzed before hand, and will effect the other variables and results. The pre-selected variables such as GMAW variation, wire type/size and shielding gas type/size are chosen before the weld job is performed, and remain constant through the job of the weld technician. Primary variables such as wire-feed speed, voltage and gas flow are set up just prior to welding, and are usually input into a program, with different programs in sequence for different levels of these parameters. Finally, secondary variables such as travel speed, arc location, stick-out and gun angle are the most readily adaptable in real-time to the needs of the application.

To further the quality of robotic welds, results should be analyzed. Measuring changes in size, shape, penetration and weld properties will help determine the limits of the weld parameters. In turn, productivity can be measured in terms of travel speed, deposition rate, on-arc time and cycle time.

Once optimized, the program and parameters will allow for an ideal combination of productivity that produces quality welds.

Check out D/F's Robotic MIG Torches

D/F Robotic Water-Cooled-to-the-Tip Machine Barrels

D/F W/C-to-the-Tip TorchesThe fully Water-Cooled-to-the-Tip Robotic MIG Standard and Series-A Machine Torches are ideal for welding at currents up to 850 amps and large diameter wires.

Very similar in design to the Linde/ESAB ST-12 but with improvements and new features, and proven to be a superior replacement alternative for the Lincoln Electric K148A & K148B, the D/F Machine Water-Cooled-to-the-Tip Torch assemblies are designed to provide long trouble-free service. With the various models available, a contact assembly selection may be made to suit individual torch head requirements.

The Model NCM torch accommodates slip-in contact tips held by a collet nut. The Model HTM torch accommodates threaded contact tips. Combined the models will run .030"-.062" hard wire, .035"-1/8" cored wire, and .035"-3/32" aluminum wire.

  • Up To 850 Amps Continuous Duty
  • Slip-In Or Threaded Contact Tip Models Available
  • Direct Replacement To Linde/Esab ST-12 & Lincoln K148A & K148B

Learn More About the D/F Water-Cooled-to-the-Tip Machine Barrels

D/F Welding Tips & Tricks - General TIG Troubleshooting

TIG Whichever type of welding you are doing, it will have a few of its own nuances that sets it apart from the others. TIG welding is no exception. Here are a few tips to help you get through some sticky situations.

  • Tungsten Contamination: Keep tungsten from touching the weld pool. If the tungsten melts, use less current or larger tungsten, whichever is appropriate.
  • Porosity: Gas flow can be too turbulent or inadequate. Condensation, dirt, grease and oil might also contaminate and create pockets.
  • Rapid Tungsten Burn Through: Tungsten might burn too fast if gas flow is inadequate, or if the tungsten is too small. Excessive heating of the torch body might also contribute to tungsten heating.
  • Post-weld gas flow (~1 sec per amp) will help prevent tungsten oxidation during cooling. It can also prevent tungsten discoloration, or discoloration and powder build-up on the gas cup.
Keeping these things in mid will help you experience a smoother TIG welding application. For more information or questions, please do not hesitate to contact us so one of our engineers can help you out.

Check out D/F's Consumables .

Got Projects? Submit Them to WIN!

We want to see how our equipment helps brings out the best of your creativity, skill, or whatever else helps you with your welding projects.

Submit your projects to:

Things to include:

  • Photos of your project
  • What did you make?
  • How did you make it?
  • Which D/F products did you use?

Project submissions will be put in a drawing for a chance to Win A Gift Card to your local Best Buy Consumer Electronics Store.

Words from the Editor

Greetings from D/F!
Thank you for reading our High Current News e-newsletter. Please share this issue with a friend and send us your comments.

Best Regards,
Dave Judd, Editor
D/F Machine Specialties, Inc.

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In This Issue
  • Quality Robotic Welding
  • Robotic W/C-to-the-Tip Torch
  • TIG Troubleshooting Tips
  • Got Projects? Submit to WIN!
  • New Products
  • D/F MLB All-Star Giveaway

New Products - Automatic W/C-to-the-Tip Barrels

The fully Water-Cooled-to-the-Tip MIG Automatic Models Water-Cooled to the Tip Machine Torches are applied to a Direct Mount Docking Spool for high current single arc welding. Very similar in design to, but outperforming the Linde ST-12 and Binzel AUT 750 with new features and improvements in water-cooling, and proven to be a superior replacement alternative for the Lincoln Electric NA-5 & NA5R feeders with K148A & K148B torches, the D/F Machine Automatic Water-Cooled to the Tip Positive Contact assembly are designed to provide long trouble-free service. With the various models available, a contact assembly selection may be made to suit individual torch requirements.
  • Up to 650 Amps Continuous
  • Slip-In or Threaded Current Tip Models available
  • Torches available in different lengths with multiple nozzle configurations

Read More

D/F MLB All-Star Giveaway
MLB All-Star

America's Favorite Pastime!


Tell us (1) who will win the 2011 MLB All-Star game on July 12 & (2) what the combined score for both teams will be. Correct answers will be put in a drawing for a chance to Win A Gift Card to your local Best Buy Consumer Electronics Store. Please submit your answers no later than July 10th.

Email us your answer!

Your Downloads

Did you know you can download all of D/F's Catalogs, Forms and Instruction Manuals at D/F's Online Download Center?
Visit the Download Center online ad D/F's web site for more information.

Contact D/F

Product Info: 1-507-625-6200
Fax: 1-507-625-6203
Online: Contact D/F

D/F Machine Specialties, Inc.
1750 Howard Drive
North Mankato, MN 56003

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© D/F Machine Specialties, Inc.
1750 Howard Drive
North Mankato, MN 56003
Phone: (507) 625-6200
Fax: (507) 625-6203

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