Unlocking the Power of nexAir KnowHow: Expert Advice on Gas and Equipment Solutions

When welding or cutting metal goes wrong, it’s rarely just bad luck. Usually, there’s a specific reason – wrong gas, incorrect settings, or equipment that isn’t quite right for the job. At nexAir, we’ve seen just about every problem that can happen in a fabrication shop, and we’ve helped solve most of them.

Getting the Gas Mix Right Makes All the Difference

Have you ever noticed how the same welding machine can perform completely differently depending on who’s using it? Sometimes it’s technique, but often it’s about the shielding gas.

A fabricator we worked with couldn’t figure out why their MIG welds on stainless kept coming out discolored. They’d tried everything from adjusting their machine settings to switching welders. It turns out they were using a gas mix that was better suited for carbon steel. A simple switch to a higher-argon mixture designed for stainless solved the problem immediately.

This happens in other industries too. Food packagers often use standard gas mixtures when specialized blends could extend their products’ shelf life by days or even weeks. Our expert KnowHow™ helps identify these opportunities that are easy to miss when you’re focused on daily operations.

Finding Equipment That Actually Fits Your Needs

Walking into a shop that’s struggling with outdated or mismatched equipment is something we see regularly. One small fabrication company had purchased an advanced pulsed MIG system because they heard it was “the best.” But their typical work – heavy structural steel in a dusty environment – would have been better served by a simpler, more robust machine.

The newest inverter-based welders are incredible for certain applications. They’re smaller, more efficient, and offer amazing control features. But they’re not always the right choice for every shop. Sometimes reliability and simplicity matter more than having the latest technology.

Gas delivery setups are another area where shops often overcomplicate things. A medical device manufacturer had installed an elaborate gas distribution system with features they never used. A straightforward setup would have cost less and been easier to maintain.

Don’t Overlook Your Consumables

It’s easy to focus on the big purchases – welding machines, gas systems, automation. But we’ve seen countless shops overlook how much their consumable choices affect their bottom line.

Take contact tips, for example. The cheapest ones might save you a few dollars upfront, but if they’re failing twice as often, you’re losing money on downtime and quality issues. A brewery equipment manufacturer we know switched to premium contact tips and cut their replacement frequency in half.

The same goes for abrasives. Using the wrong wheel for material prep can double your grinding time and still deliver worse results. Small changes in this area help operations Forge Forward without major equipment investments.

As for filler metals – the differences between standard and premium options become obvious in challenging applications. One structural fabricator switched to a higher-grade wire for their outdoor work and virtually eliminated the porosity problems they’d been fighting for years.

Tackling Those “Problem Child” Materials

Some materials just have a reputation for being difficult. Aluminum, high-strength steel, and certain stainless alloys top the list. But they’re usually not as problematic as people think.

With aluminum, proper cleaning and the right filler selection solve most issues. For high-strength steels, controlling heat input makes all the difference. And stainless steel welding problems almost always come down to contamination or inadequate shielding.

A custom vehicle manufacturer couldn’t figure out why their aluminum welds were failing quality checks. They’d blamed everything from their welders to their equipment. In reality, their pre-weld cleaning process wasn’t removing all the oxide layer – a simple procedure adjustment fixed what they thought was a major problem.

Making Changes That Actually Stick

The hardest part of improvement isn’t knowing what to change – it’s successfully implementing those changes. Start small, document your results, and build on successes. Industry forums, manufacturer training programs, and local welding organizations can provide valuable insights tailored to your specific challenges.