Maximizing Welding Productivity: Tips from nexAir’s Welding Automation Experts

Productivity in welding is rarely about one big fix. It comes from fine-tuning—adjusting gas flow, tightening cycle times, selecting the right shielding blend, and streamlining delivery systems. At nexAir, our welding automation experts work closely with manufacturers and fabricators to help increase output without compromising quality. That means smarter gas integration, cleaner weld environments, and systems that work with your team, not against it.

Gas Selection That Supports Speed and Stability

In fast-paced environments, welding gas does more than shield—it sets the pace. The right blend helps maintain arc stability at higher travel speeds and reduces spatter cleanup, which directly translates to more parts per hour. We help customers match gas to process and base metal so each weld is consistent and repeatable, shift after shift.

For example, a 90/10 argon-CO₂ mix often improves deposition in automated MIG applications. With TIG, the right helium ratio can reduce pass counts on thicker sections. These aren’t just lab-tested ideas—they’re based on what works in the field, backed by our decades of KnowHow™.

Flow Control That Keeps Things Moving

Too much gas wastes product. Too little risks defects. Dialing in delivery matters just as much as blend. Our team helps you set proper flow rates based on tip size, process type, and robot movement. We also review regulator health and install monitoring systems where appropriate, so pressure and flow stay within target ranges. Even small adjustments can lead to faster starts, better fusion, and tighter arc control.

For multi-station setups or robotic cells, we recommend centralized manifolds or microbulk systems to eliminate downtime between swaps. This keeps operators focused and ensures automated systems stay powered without interruption.

Minimize Downtime with the Right Delivery System

The best automation in the world still stops cold when gas runs out. We help eliminate unplanned downtime by matching delivery systems to your production schedule. From high-capacity bulk installations to low-maintenance microbulk setups, we build programs that scale with your operation and reduce manual handling.

Our telemetry systems track consumption patterns and alert us when a refill is coming due. This keeps supply predictable and frees your team from monitoring tanks and placing orders. It’s one more way nexAir helps you stay focused on throughput instead of logistics.

Weld Smarter, Not Just Faster

Speed is only useful when the results hold up. We look at everything around the arc—gas quality, weld envelope, torch angles, joint prep—and offer practical changes that improve performance without sacrificing accuracy. This often includes reviewing existing gas usage and recommending process-specific blends that offer better penetration or fewer defects at higher speeds.

In many cases, the right gas upgrade allows customers to reduce post-weld rework, clean less, or move to single-pass techniques. Those improvements add up quickly across a full production run.

Training That Reinforces Every Upgrade

Automation only delivers when operators understand the system. Our team works on-site to review gas handling, teach flow optimization, and explain how specific blends impact weld behavior. This knowledge stays with your crew and helps maintain gains long after installation. We tailor each session to your workflow and processes, so training fits what your team actually sees on the floor.

Moving Forward With the Right Tools

When you’re ready to expand, take on new materials, or tighten up your existing process, your gas program should move with you. At nexAir, we help you Forge Forward by combining expert guidance with dependable supply. That means fewer slowdowns, stronger welds, and systems that adapt as your goals evolve.

Ready to Improve Performance?

Every weld counts—so does every improvement. If you’re looking to increase output, reduce rework, or upgrade your delivery systems, our welding automation team is ready to help. Contact nexAir today to start the conversation. We’ll help you build a gas strategy that supports your next level of productivity.