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.
- AWS Members, extensive latest edition resource Library maintained.
WELDING PROCESSES employed:
MIG welding – (GMAW-S, GMAW-P, GMAW)
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, PW
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, A588, 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 – 3003, 5052, 5083, 5086, 6061, and 6063
Expanded Metal – Flattened and Standard; Steel, SS, Al
FILLER METAL usage:
ER80/90S-D2, ER70S-6, and E100/110S
E70C, and E90C-D2
ER308L, R309L, R347, RNiCrMo-2
ER5356, E5183, and ER4043
SHIELDING GASES utilized:
90/10 (Ar+CO2) 95/5 (Ar+O2) 100% Ar (Argon)
75/25 (Ar+He) 75/25 (He+Ar) 75/25 (Ar+CO2)
95/5 (Ar+CO2) 98/2 & 95/7.5/2.5 100% He (Helium)
WELDING QMS (Quality Management System)
- In-house qualification to AWS (American Welding Society) D1, B codes, and MIL-STDs:
TACOM Ground Combat Vehicle Welding Code-Steel
- PQRs (Procedure Qualification Records)
- Bend Tests
- RT/UT (outsourced)
- Tensile tests (pulls outsourced)
- WPSs (Welding Procedure Specifications)
- Weld Information Boards
- WPS matrices
- Continual training
- WPQRs (Welder Performance Qualification Records)
- Welder Continuity Logs and Matrices
- Welder Wallet Cards
- RT (outsourced on occasion)
- Bend Tests (performed internally; preferred over RT)
- CWI two (2) Certified Welding Inspectors and one (1) CAWI 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 & both min. & max. 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
- NDE; 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.