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Quality control is a huge part of any fabrication process, especially metal fabrication. Utilizing a quality control manual can help your company be more efficient, successful, and provide better finished products to your customers. Regardless of what sort of metal fabrication services you provide, quality control should be at the forefront of your mind. Ranging from storing materials, moving materials, and even the equipment and access to the workspace should all be outlined in a quality control manual. This manual should also include all industry guidelines and safety instructions.

Quality control is critical to fabrication for a variety of different reasons. Most importantly, it helps to ensure high-quality finish results, but there are additional benefits as well.

Safety

Safety is a huge part of welding and metal fabrication, and should be at the forefront of any quality control manual. This quality control guide can help ensure fabrication facilities are up to code, and that both materials and employees remain safe.

Compliance

Compliance is another huge factor in quality control and safety. Complying with the codes, set forth by the American welding society, OSHA, and ASME ensures that your company can avoid violations and fines.

Cost

Quality control can also help with the bottom line. Cost control is a huge part of standard setting and can ensure your projects return a healthy margin. Noncompliance fees, injuries, and loss and productivity can all impact the cost of doing business.

Consistency

When working in metal fabrication consistency is also a big part of quality control. Quality Control manuals can ensure clients expectations are in line with the standard of the fabricators. These guidelines ensure projects are done to a certain standard.

Reputation

Reputation is big in the metal fabrication world, and Quality Control can help protect a welder’s reputation. The quality control process shows that your fabricators produce a certain level of quality and that your project will live up to the promises you made.

Quality control manuals for metal fabricators should standardize and document all of the quality control processes a manufacturer has enforced in their facility. This quality control guide is designed to produce high quality goods and services. The steps to achieve high-quality metal fabrication are outlined in the management guide.

Simply put, a quality control manual outlines your company’s policies, goals, and methods. Beyond the basics will also include information about procedures, systems, employee roles, and other business specifics. Many quality control manuals include safety programs, expectations of finished products, and information about troubleshooting different scenarios.

While a quality control manual may seem like an unnecessary formality it is integral in business activities and can boast growth and productivity increases. Based on the type of metal work you do fabricators may have questions about new procedures if they have never worked in this specific field of metal fabrication previously. When working in specific types of metal fabrication the quality control manual can help ensure the standards will meet the customers needs and there is an expected quality.

Quality control manuals can also help with client communication. When there is a written document, spelling out the processes and standards of a company, it is easier to communicate with clients on what they may expect from you. A very specific quality control manual may take time in the beginning, but save time in customer relations, and answering specific questions.

Quality control manuals can help show potential clients that your metal fabrication will meet their standards. By outlining standards in an official document, you can dispel some concern and distrust. Customers often find that fabricators that offer quality control manuals are more legitimate and more trustworthy.

In the end, a quality control manual is a great guide for both employees and potential clients. Quality Control manuals also display the variety of projects a fabricator is willing to take on. The ability to set standards for projects for both employees and clients can help eliminate confusion and complaints. Quality Control manuals also help with safety and other concerns. Jack’s Metal Works is a great resource for all things metal fabrication in Boise, Idaho. We would love to meet with you about your metal fabrication project no matter how big or small.

Tack welding is a specific process in which you apply a small dot-like bead along the joint length before the final weld is completed. The amount of dots or tacks needed will change based on the material thickness, metal type, geometry of the joints and the length of the weld. 

Tack welding is an important skill for any welder and should be learned as one of the fundamental skills in welding. Tack welds are used in nearly every welding project and are very important in welds with complex joints. 

The Purpose of the Tack Weld

The tack weld is designed to create a proper alignment that is held in place for when the actual weld is performed. While the tack weld is not part of the main weld it still needs to be done properly and when done improperly can cause lots of issues. Tack welds allow the joint to be held in place without the use of clamps but clamps and magnets may be used for some projects. Tack welds can hold up to the stress created by welding keeping the joints and metal in alignment. Tack welds don’t restrict access the way clamps do allowing a welder to access all points without restriction. The internal stresses of welding like metal expansion and contraction can cause the joint to warp and separate but the tack welds keep it in place. 

Size and Amount of Tack Welds

Tack welds have to stay small so they can be incorporated into the final weld but still be large enough to hold the panels together properly. The balance can be challenging but tack welds should never be larger than the final weld. An example of this is if the weld joint is going to be ½-inch wide you should keep your tack welds to 5/8-inch wide or smaller. If the tack welds are too large the weld shape can be affected and cause a stress point 

When choosing the size and amount of tack welds there are a lot of factors to consider. First consider internal stresses. The larger the final weld the more stresses the tack weld will be subjected to. Next the length of the joint should be considered, longer joints need more tack welds. The complexity of the joint is also important and a short complex weld may need more tack welds than a long simple joint. The material thickness is also something to be considered, thinner material often needs more welds. The position of tack welds is as important as the amount and size. 

Depending on the type of weld being performed tack welds are performed differently. Tig welding, stick welding, and MIG or FCAW welds all have specific methods for creating a tack weld. 

There are a few different methods of applying a tack weld. The standard tack weld is placed on the joint and will be conceded by the final weld. This is designed to hold the pieces together so the final weld can be performed. The Bridge tack weld is used on joints that need a root opening like a pipe. This tack weld bridges the gap. This method requires more skills than the standard tack weld. Finally the hot tack weld is used to close a significant gap. The tack is excessively heated and then hammered into place. The high heat can help to create a contraction bringing the parts together. 

When done properly tack welding is a great method for joining materials before the final weld. A tack weld is a vital part of any welder’s skill set and can be a great method for joining materials prior to the final weld. Jacks metal works can help with welding projects of any size. We are happy to work with you on your welding project no matter how big or small. Our team is highly skilled and can perform welds ranging from basic to highly technical.

Each type of metal has a unique welding process based on the finish and thickness of the material and what the finished product will be. There are a variety of different welding types that work for stainless steel but three most common options. The most common welding methods for stainless steel are MIG welding, TIG welding and resistance welding. 

Stainless steel is an alloy metal that is iron based and contains chromium. The chromium makes stainless steel more resistant to corrosion and most stainless steel has between 11% and 30% chromium. The unique chemical attributes of each metal type requires unique welding methods and techniques. Stainless steel is very strong and can resist chemical corrosion as well as many different liquids and gasses. The strength and resistance to contaminants is what makes stainless steel such a popular metal for fabrication. Stainless steel is very durable and doesn’t tarnish easily. Stainless steel comes with a hefty price tag often costing 5x more than mild steel. 

MIG welding or Gas Metal AC welding is a semi-automatic process that creates a strong joint between two pieces of stainless steel when executed correctly. When performing a MIG weld you need argon rich shielding gas and a solid wire electrode. This method is popular because of the pulsed current supply that is utilized by the welder. This method can get into tough to reach spots and is great for more intricate welds. Gas mixtures like carbon dioxide, oxygen and helium are used to help stabilize the arc and improve the quality of the weld. 

TIG welding or gas tungsten arc welding is a great welding option for longevity and versatility. The TIG method is the most common option when welding stainless steel. The quality of this weld is very good and creates a strong bond. Thin material is an ideal candidate for this type of weld because of the low heat input. Argon gas is mixed with other gasses based on the project to create the right combination. The argon gas can be mixed with nitrogen, helium and hydrogen. If oxidation and corrosion resistance are a priority a single-sided welding process can be utilized to create an inert backing gas protection between the exterior and interior welds. 

Resistance or spot welding is a great stainless steel welding option and is the most economical welding option for stainless steel. Resistance welding equipment can be used on a variety of jobs ranging from small to large. This welding method uses an electrical current to heat the edges of the metal and seal them together. This technique works especially well for metal that has a lower melting point and the heat can be adjusted to prevent distortion. 

Choosing the correct welding method for your stainless steel job depends on the unique characteristics of your project. If you are looking for a cheaper welding option spot welding is a great option, if you have thin sheets of stainless steel you may choose TIG but if you have thicker sheets MIG may be your best option. 

The team at Jack’s Metal works can help determine the best welding option for a stainless steel project. The years of experience that the Jack’s Metal Works team brings can ensure the proper welding technique is utilized and done properly. Like any project the quality of the work is not just in the process chosen but also in the technicians ability. Jack’s Metal works can weld all types of metals not just stainless steel. If you need help with a welding project no matter how big or small we are here to help. 

When working in metal fabrication safety is a top priority. Safety practices help to protect both the shop and employees. When the health and safety of workers is a top priority, productivity and quality increase. 

Creating safeguards for welding tasks can be a challenge because of the smoke and hazardous spatter. Welding different materials like stainless steel, nonferrous chromium alloys and other similar materials can create toxins like hexavalent chromium which is dangerous for the respiratory system. Welders face many risks if safety protocols are not in place. Some of these potential risks include splatter and spark burns, rashes and skin ulcers from exposure to toxic fumes and cutting mishaps caused by poor visibility. Other potential issues include perforations in the nasal septum, asthma or lung cancer. Beyond risks to specific individuals there is the risk of combustible gasses building up and causing an explosion which puts the entire shop at risk. Training and equipment can make a huge difference in preventing these sorts of mishaps and potentially dangerous situations. 

Every welding shop should have safety first welding practices implemented. Education is the best way to prevent material handling and equipment operation mistakes.Metal fabricators need to have safety training programs. Training should include a variety of different topics including the use of PPE with a special focus on welders hoods. PPE should be well maintained and inspected to ensure it is up to standards. Protective clothing like welding aprons and gloves should be inspected to ensure there are no holes or tears. Goggles and face shields should be inspected for scratching which may impact visibility. Falling objects are hard to see when using welding PPE and welders need to be in a safe spot when welding. 

Hot Spatter is a big safety hazard for welders. When welding spatter can be generated when the incorrect welding settings are used or the metals of different thicknesses are being worked on. Hot spatter can spread as far as 35 feet and can cause eye injuries, burns and other spark-fire hazards. Some ways to protect your team from spatter is to use a welding hood and shield to protect the face and eyes. Leather gloves should be worn to protect the hands from spatter and the heat of the spatter. Leather aprons or vests can be used or a welding suit. Proper training and examples can help prevent spatter. 

Air quality is another big risk for welders. Fumes can be deadly and proper ventilation and fume extraction should be part of any welding facility. When working with materials like lead, stainless steel, copper and zinc welders need to be conscious of the toxic fumes that are being produced. There are lots of options for removing and protecting against air hazards. Fresh air goods are a great way to protect welders from fumes. Ventilation systems can also help keep the air quality safe. PPE plays a huge role in air quality. 

A properly trained welder is a safe welder. Jack’s metal works prides themselves on being a safe place to work and offers high quality metal works for customers. As metal fabricators we know that safety and quality work go hand in hand and believe the work provided by Jack’s Metal Works speaks volumes about both. If you are looking to work with a quality custom metal fabricator Jack’s Metal Works is a great option. Our team of experienced welders can handle any project no matter how big or small. 

Protecting Grain and Feed with Steel Storage

Water is one of the most necessary elements on earth but moisture and grain storage are not a good combination. Moisture intrusion can destroy all the grain in a hopper, silo or other storage system. The moisture levels in the storage system have to be properly maintained, 12% moisture can lead to condensation and caking in your storage container. Moisture also causes metal to rust and can cause severe damage to a steel storage system. Chipped mail is one of the most common spots for rust to begin and then seep into the structure of the storage unit. Rust is a huge issue for steel structures. While these issues may be big they are steel detailing techniques that can help protect the steel from water and fluctuating temperatures. 

A great way to protect your silos, hopper or feed storage system is through hot-dip galvanizing. This method is one of the most cost-effective options for steel detailing. The hot-dip galvanizing method coats the metal in a corrosion-resistant zinc. This method is also called batch or after-fabrication galvanizing. This method taxes a few intricate steps to properly protect the steel. The fabricated surface first needs to be cleaned to remove mill scale, grease and oil from the surface. The metal is then dipped in a vat of molten zinc with additives that are designed to protect the surface, this dipping process ensures every edge and crevice is coated. The zinc bath reacts with the steel to create the corrosive protective layer. 

After the coating process areas of the hopper or silo may need to be welded to allow them to continue to function without grinding on the coating. The working parts can be subjected to friction if not welded after the coating. Welders need to consider the HDG when welding. The welds may not hold up to the dipping process.When steel detailing a spot or metal arc welding system may be needed during the fabrication process. The zinc can penetrate the weld spots if precautions are not taken and this can lead to cracking. Push welding is recommended over pulling welding to ensure spots stay intact. 

If any welding is needed after the HDG it will need to use materials that work with the zinc coating. If the welder needs to use metal fasteners that should have the same corrosion resistance at the zinc coating to ensure they don’t cause premature failure. Welding zinc coatings can cause toxic fumes and ventilation and air filtration is required. 

Proper design is a huge factor in how well a silo performs. When a steel storage system is properly designed structural problems are greatly reduced and the hot-dip galvanizing process further reduces the risk. Metal thickness is another factor to consider. Overlapping areas can cause coatings to wear quicker. Full service metal fabricators will take all the aspects into consideration and create a structurally sound feed storage system that will protect your investment. 

While the steel structures detailing is a huge factor in protecting grain and feed there are other things to consider as well. Proper venting and draining are also vital factors to consider. The foundation is an additional element to consider. 

Jack’s metal works can assist with welding and other aspects of your steel feed storage system. Jack’s welders have experience welding galvanized metals and have the tools and experience to get the project done properly.