Advanced Welding Techniques: nexAir KnowHow Shares Expert Tips for Skilled Welders
Welding isn’t just about joining metal – it’s about creating something built to last. For seasoned welders, the most minor adjustments can yield the most significant gains. At nexAir, we’ve gathered tips straight from the floor — from the people who weld for a living and keep pushing their craft forward.
Mastering Pulse MIG: Beyond the Basics
Most welders know the basics of pulse MIG, but few unlock everything it can do. Real gains come from dialing in the machine — not just setting it and striking an arc.
Take aluminum, for example. Many of our customers swear by running a slightly higher pulse frequency than the manual calls for. It helps produce cleaner beads and keeps heat distortion in check. When working with stainless, especially on thinner stock, backing off the heat just a little can lead to tighter, more consistent results.
The trick is in the trial runs. Keep a running log of what settings worked on which jobs. Over time, it becomes your own go-to playbook — more valuable than any default chart. That kind of hands-on refinement is what we mean when we talk about helping our partners Forge Forward, even on the toughest builds.
Precision TIG Welding: The Small Details Matter
TIG welding is where patience meets precision. And while most welders have their rhythm, a few subtle shifts can elevate the final product.
Cup size, for one, is more than just about gas coverage. Switching to a larger cup — even when it’s not strictly required — gives better visibility on tight or intricate joints. The same goes for tungsten prep. Grinding the tip lengthwise rather than across helps maintain a steady arc and cleaner start.
Heat control is another big one. Instead of rushing through long seams, use tack welds to spread out the heat and reduce the risk of distortion. It’s a small habit that makes a big difference, especially when aesthetics and strength both matter. These tips come straight from our KnowHow™ sessions — developed with the day-to-day realities of welders in mind.
Gas Selection Secrets for Superior Finishes
Shielding gas is often treated like an afterthought — but the right mix can completely change your results.
Working with carbon steel and want a better-looking weld? A tri-mix blend with a bit of added oxygen can smooth out the bead and cut down on post-weld cleanup. On stainless, adding helium produces brighter welds with fewer oxides and less brushing afterward.
And don’t forget flow rate. Too high, and you create turbulence that pulls in air. Too low, and you’re left with poor shielding. Most applications perform best between 15–25 CFH — but your shop setup, joint type, and torch angle all factor in. Adjust accordingly.
Troubleshooting Weld Issues: What to Check When Nothing Makes Sense
Some problems don’t show up until you’re halfway through a weld — and by then, you’re already chasing fixes. That’s why real troubleshooting starts with knowing where to look first.
If you’re seeing porosity, don’t just re-clean the surface. Look around your workspace. Drafts from nearby doors, fans, or even HVAC vents can disrupt your gas shield without you noticing.
Wire feed acting up? Before adjusting tension or swapping tips, inspect the liner and check for bends or debris in the cable. Those hidden issues cause more headaches than worn drive rolls ever will.
And if you’re prepping metal, remember: “looks clean” doesn’t always cut it. Oils, coatings, or even fingerprints can throw off an otherwise solid weld.
The more methodical your approach, the fewer surprises you’ll face on the job. Over time, pattern recognition becomes second nature — and that’s when troubleshooting turns into real skill.
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Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.
The Hidden Costs of Gas-Related Downtime
When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:
- Production rescheduling that disrupts carefully optimized sequences
- Rush shipping fees to meet customer deadlines despite delays
- Quality inconsistencies when processes restart after interruptions
- Overtime costs to catch up after unplanned stoppages
- Reputation damage when delivery commitments are missed
For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.
From Reactive to Proactive: The Supply Continuum
Most facilities follow a predictable pattern in their gas management evolution:
Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.
Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.
Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory.
Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.
Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.
Customizing Solutions for Maximum Uptime
Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:
- For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
- For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
- For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
- For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.
This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.
Beyond Traditional Supply: Integrated Services for Total Reliability
Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:
Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions
These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.
Measuring Success: The Results That Matter
The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:
Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability
These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.
Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.
Looking out for your future
Get your career going on the right track with nexAir
Find out how nexAir KnowHow has impacted businesses all over the Southeast
Our expertise makes us more than a valuable partner, it makes us headlines
