Rochester Welding specializes in TIG, MIG, and robotic welding produced by seasoned professional welders. We have a vast library of qualified welding procedure specifications that includes various grades of stainless steel, carbon steel, aluminum and steel armor plate using both semi-automatic and manual welding processes.
UPSTREAM core competencies:
- Drawing review and aid in bidding prospective projects with PMs and Estimating Dept.
- Make use of APQP and manufacturability & constructability reviews
- Involved in related manufacturing and processing team discussions
- Collective fixture conception, collaboration, and team review with Design Eng. Dept.
- Acquire, obtain, and implement proper welding equipment and best practices in effort to obtain code-level welding quality in a highly efficient manner.
WELDING PROCESSES employed:
MIG welding (GMAW-S, GMAW-P, GMAW Globular & Spray)
TIG welding (GTAW)
MIG-Aluminum (push-pull GMAW-P, GMAW-Spray)
Robotic MIG welding (Automatic GMAW-S, GMAW-P, and FCAW-GM)
Resistance Spot/Projection Welding RSW
Flux Cored Arc Welding FCAW-GM
Preheating and Interpass Temperature control
BASE METALS used (typical and “standards”):
Armor 12560, 46100, and Domex Alloys
Carbon Steels A36, A500, A513, A1011HR, A100CR, C1020
HSLA (High Strength Low Alloy) Steels A572 Grade 50, A656
HTLA (Heat Treatable Loy Alloy) Steels A514 Grade B & H, A519 Grades 4130, & 4140
Stainless Steels and Nickel alloys 304/304L, 316/316L, 321, Hastelloy X
Aluminum; Non Heat Treatable and Heat Treatable 5052, 5083, 5086, 6061, and 6063
Expanded Metal Flattened and Standard; Steel, SS, Al
FILLER METAL usage:
ER80/90S-D2, ER70S-6, and ER100/110S
E70C, and E90C-D2
R308L, R309L, R347, RNiCrMo-2
ER5356, ER5183, and ER4043
SHIELDING GASES utilized:
95/5 (Ar+O2) 90/10 (Ar+CO2) 75/25 (Ar+CO2) 98/2 (Ar+O2)
75/25 (Ar+He) 100% Ar (Argon) 95/5 (Ar+CO2)
WELDING QMS (Quality Management System)
- In-house qualification to AWS (American Welding Society) D1, B1 codes, and MIL-STDs:
TACOM Ground Combat Vehicle Welding Code-Steel
B2.1-Specification for Welding Procedure and Performance Qualification
- PQRs (Procedure Qualification Records)
- Bend Tests
- RT/UT (outsourced)
- Tensile tests (outsourced)
- WPSs (Welding Procedure Specifications)
- Weld Information Boards
- WPS matrices
- Continual training
- WPQRs (Welder Performance Qualification Records)
- Welder Continuity Log,
- Welder Wallet Cards
- RT (outsourced)
- Bend Tests
- CWI (two (2) Certified Welding Inspectors) oversight before, during, and after welding
- Filler Metal and Shielding gas CoCs, official reports, PPAP packages, Weld Maps.
- Process Monitoring
- Use of calibrated Fluke 275 Amp-Voltmeter to verify adherence to WPS amperage, voltage, and Preheat & Interpass temperature essential variable ranges.
- GTFM (calibrated Gas Turbine Flow Meter), shielding gas flow verification.
- Destructive Testing by way of
- Cut & Etch; -macroetch and macrograph capabilities for Carbon/Alloy Steel, Stainless, and Aluminum.
- Pry & peel and RSW button/nugget testing
- Torsion/Torque testing for projection weld nuts and studs
- Push-out testing for projection welded nuts and studs
- NDT; 3rd Party ASNT Level II RT, PT, UT, MT services on call (Lab or Call out)
- Job kitting; components and details for weldments are kitted with job traveler and drawings
- Welders, Welding Engineer, and CWI discuss (line-up) work before fabrication begins.
- Certified WPQRs in 2G for plate, and 2G, 5G, & 6G for tube and pipe for all RWCI typical base metals.