Welding machines are the base of metal fabrication and contribute widely to a variety of industries including construction, shipbuilding, automotive, aerospace, oil and gas, and many more.
Now imagine your welding breaking down mid-work. Now, that’s definitely not something that you’ll appreciate, especially since it would cause downtime, interrupting the workflow.
So instead of waiting until the machine shuts down, why not enhance its durability with daily check-ups beforehand? That’s what we are going to discuss in this blog: the essential maintenance tips for the welding machines.
Why is Maintenance Important?
Lack of proper maintenance will cause even the most top-tier machine to malfunction. As far as welding machines are concerned, equipment failure adversely affects the overall production. So, here are a few maintenance tips to ensure the longevity of welding machines:
- Routine cleaning
A significant amount of heat and spatter will be generated during the welding process. Spatter and other dust and debris can accumulate on the machine’s surface over time.
So it is advised to conduct a routine check-up that involves the cleaning of exterior components, such as filters, vents, spillages and other internal components with either a vacuum cleaner or a soft brush.
- Check the Cooling System
Cooling systems are an integral part of the welding machines. Some may be inbuilt, while some may require external coolers. It can be air-cooled or water-cooled, depending on the machine.
Either way, the coolers are essential in regulating the welding machine’s temperature. If it features cooling fans, make sure that it’s free from dust particles. For the external cooling systems, check for the coolant level and the condition of the pumps and hoses.
- Inspect the Cables
Inspect the cables and connections. Over time, the cables may become damaged or frayed, resulting in exposed wires. If such a situation arrives, immediately replace the worn-out cables and wires.
- Manage the Electrodes
Electrodes are one of the most important components of the welding machine. It initiates the welding arc, generating the heat energy and fusing the metals.
Damaged electrodes will affect the quality of the product as they can lead to inconsistent welds. So, check the electrodes for damage and replace them if necessary.
Baking is another process done in industrial settings, wherein the electrodes are baked in a preheated oven (approximately 100 degree Celsius) .
Once the baking process is completed, the electrodes are kept at the holding temperature in order to maintain the dryness and also to prevent moisture absorption during the cooling process.
- Calibrate the machine
Calibrating the machine is yet another crucial step. It involves using the necessary tools such as a voltmeter, an ammeter, a flowmeter and a load bank to assess the functioning of the welding machine.
Calibration is crucial to make sure that the machine is working within the specified parameters. This will ensure consistent weld quality, reduced material loss, and thereby increase productivity.
Maintenance is not just about extending the service life of the machine. It ensures safety, durability, and overall performance. Therefore, it is important to schedule daily check-ups and incorporate the above-discussed measures to get the desired output.
At Kistler , we provide not only excellent machinery but also dedicated services to ensure the durability, longevity, and reliability of the machines, ensuring customer satisfaction.
