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

E308LT1-4

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:

D1.1-Steel

TACOM Ground Combat Vehicle Welding Code-Steel

D1.2-Aluminum

D1.3-Sheet Steel

D1.6-Stainless

B2.1

D17.1-Aerospace

PQRs
(Procedure Qualification Records)

  • Development
  • Macroetch/macrograph
  • Bend Tests
  • Brinell
  • RT/UT (outsourced)
  • Tensile tests (pulls outsourced)
  • Write-up

      WPSs
      (Welding Procedure Specifications)

      • Write-up
      • Weld Information Boards
      • WPS matrices
      • Continual training

      WPQRs
      (Welder Performance Qualification Records)

        • Training
        • Testing
        • Certification
        • Welder Continuity Logs and Matrices
        • Welder Wallet Cards
        • RT (outsourced on occasion)
        • Macroetch/macrograph
        • Bend Tests (performed internally; preferred over RT)

      WELDING INSPECTION

      • 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

       

      WELDING OPERATIONS

        • 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.

      WELDING EQUIPMENT

      GMAW

      • 9 – Miller DeltaWeld 350 Dual Feed
      • 2 – Lincoln PowerWave 455M
      • 1 – Miller XR AlumaFeed
      • 1 – Yaskawa Motoman powered by Lincoln Robotic Welder

        GTAW

        • 1 – Miller Dynasty 280
        • 3 – Miller Dynasty 350
        • 1 – Lincoln Precision TIG 375
        • 1 – Lincoln Aspect 375
        • 1 – Miller Dynasty 400

          RSW

          • 1 – Spot Weld Inc. Press Rite spot welder w/ WT6000 MFDC Welding Control

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