Welding techniques: Carbon Arc Gouging (CAG) welding

Our monthly column on welding is back. Today we are talking about CAG welding, also known as gouging.

How does it work?

CAG welding is an arc cutting process used to make grooves and recesses.

It creates an electric arc between the tip of a carbon electrode and the metal that needs to be welded. The electrode is coated with graphite and a copper layer to increase conductivity.

At these temperatures the metal melts and a high-speed jet of air is gusted along the electrode to remove the worked upon area, leaving a clean groove.

When to use Carbon Arc Gouging (CAG) welding?

The CAG process is particularly suitable for removing poorly executed welds and repairing cracks as there is no thickness limit.

Since carbon arc welding does not rely on oxidation, it can be applied to a wide range of metals.

However its versatility and speed results a generally wide and non-precision cut.

Want to know more? Want to know more? Discover our range of engine driven welders by clicking here and follow us on social media to be kept up to date.

Welding techniques: TIG welding

New year… new edition of our monthly column on welding!

Today we are talking about TIG (Tungsten Inert Gas) welding. A technique that is particularly suitable when a high level of aesthetics is required.

How does it work?

Heat is produced by an electric arc between an infusible tungsten electrode and the material that needs to be welded, in an inert gas atmosphere.

The most common gases are Argon and Helium, which are used separately or in a mixture.

Welding is carried out by fusing the edges of the piece that needs to be welded and manually adding the filler material using a welding rod.

Types of ignition

The welding arc can be triggered in three ways:

Scratch Start, when the electrode tip touches the surface, generating a short circuit.

Lift Arc, when the electrode tip, at a very low current level, is placed on the surface and lifted just slightly.

HF Ignition, when the electrode does not touch the surface that is being welded. The electric arc is generated by the high voltage at high frequency on the torch, and it is in this way that a myriad of sparks ionise the gaseous atmosphere between the electrode and the workpiece, triggering a passage of current.

Which metals can be welded?

Stainless steel, aluminium, cupronickel, copper, iron and special alloys can be welded.

TIG welding requires a great deal of manual skill. This is because when using the welding rod the for addition of filler material, one must prevent the electrode from sticking to the surface. Moreover, minimize the risk of contamination of the weld pool by tungsten, especially with the Scratch Start.

Due to the high precision and slow process, this technique is therefore suitable for visible welding on small material thicknesses.

Want to know more? Discover our engine driven welders range by clicking here and follow us on social media to keep up to date.

Genset: security and innovation are tailor made

At Genset we work to meet the specific needs of our customers.

It is from this desire that the MPM 15/400 MSA 400 Ampere was born, an engine driven welder that meets specific requirements for safety and ease of transport.

This product is emblematic to our “tailor-made” approach. Our Research and Design team prioritise your needs, allowing them to create both unique and cutting-edge solutions for you.

It is in this context that, in 2021, we carried out a major order for a high-value customer who has specialised for more than 120 years in the rental and sale of machines such as the MPM 15/400 MSA and equipment for industry, construction, events and more.

Product safety

The MPM 15/400 MSA is equipped with a bunded tank to contain unintentional liquid spills as well as protect the environment. It is equipped with the MSA safety system to work in a safe and controlled environment.

How does the MSA system work?

The MSA safety system allows the operator to stop the unit when leaving the workstation, through the use of a connector and a safety key installed on board.

With this technology, the instrument panel of the welding machine can only be used whilst the safety connector inserted. If you take the connector with you, you can be sure that the unit will be switched off until the operator returns.

What if the connector is lost?

In a special hidden compartment, you may find the emergency key, which allows the unit to be reactivated without the connector, whilst at the same time remaining safe.

The objective of the MSA system is to prevent accidents and injuries due to possible distractions, protecting the safety of workers.

Ease of transport

Ease of transport is, after safety, the second key element of this product, as it has compact dimensions and is equipped with a custom-made trolley with two pneumatic wheels and a drawbar to facilitate handling operations.

Are you looking for a product that perfectly suits your needs?

Contact us for a tailor-made consultation, our team will be happy to contribute to your projects.

Welding techniques: MIG/MAG continuous wire welding

We are back with our monthly column about welding, which describes the main techniques, accessories and materials that you need to know in order to choose the best welding machine suited to your needs.

Today we are talking about MIG/MAG continuous wire welding.

This technique is based on the fusion of a welding wire, generally solid metal, through heat generated by the electric arc.

The wire is automatically fed into the fusion bath under gaseous protection, by means of a torch connected to the positive pole of the welding machine. The wire feeder then conducts the wire from the torch to the workpiece.

Throughout this process, the gas plays the same role as the electrode coating, i.e. it protects against oxidation and allows slag-free working.

What is the difference between MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding?

Depending on the gas protection, we distinguish between two types of continuous wire welding:

MIG (Metal Inert Gas) welding is achieved by using an inert gas that does not participate in fusion, such as Argon or Helium.

MAG (Metal Active Gas) welding, on the other hand, is based on the use of an active gas, such as CO2 or ArCO2 mixtures in different percentages, depending on the material that is being welded. In this case, the gas takes part in the fusion.

How and what may be welded with a continuous wire welding machine?

Continuous wire welding is ideal for carrying out a large number of welds with high filler volumes. It may be used on engine driven welders with electronic welding control.

It is a very versatile technique and rather easy to handle. It is, however, preferable to weld indoors to prevent weathering to take place, stripping it from the gaseous protection.

It is usually used for welding steel, light metal alloys, copper, nickel and titanium.

The equipment is rather bulky and therefore difficult to transport, as the gas cylinder must also be carried.

Want to know more? Click here to find out more about our engine driven welders or write to us for a tailor-made consultation.

The Briggs & Stratton powered Genset range has been extended with a new engine driven welder

The MPM 5/200 IELBN engine driven welder is the new addition to the Briggs & Stratton powered range.

The features

• Lightweight, safe and easily transportable, it is also available with a trolley for effortless handling.

200 Ampere DC coated electrode welding, which may be used as both a generator and welder simultaneously (within the power limits of the machine).  

• It has a 4,5 kVA three-phase and 3,6 kVA single-phase AC generator.

6,6 litre fuel tank which results in two hours’ working autonomy.

• Set up for remote control operation, allowing one to comfortably adjust the welding current from the workstation. Once connected to the front panel connector, the remote control is immediately operational.

The Briggs & Stratton engine

The engine driven welder is equipped with a Stage V XR 2100 petrol engine from Briggs & Stratton, a world leader in the production of air-cooled petrol engines.

It is reliable and fuel efficient, as well as meets the most stringent emission regulations.

For further information please download the product data sheet and do not hesitate to contact us for a tailor-made consultation.

Genset brings innovation to METSTRADE Amsterdam

The boundaries between innovation and sustainability are shrinking.

This year at METS – Marine Equipment Trade Show 2021 we will present our latest innovations at stand 03.544, Hall 3.

The trade show is a global exhibition dedicated to the leisure marine industry taking place in Amsterdam from 16 to 18 November.

The new Genset marine generators combine design, high performance, ease of installation and low noise for a concentration of innovation.

Safe, durable and reliable, they are the result of careful research and cutting-edge technologies, which are able to meet the needs of those who go to sea for profession or passion, without forgetting the environment.

We will exhibit the following models: GVi 8550 and the GSi 3500.

The 2021 nautical range and their features

GVi 8500: 8 kW of continuous power, equipped with a Kubota engine with variable speed. It has sustainable technology that allows the engine rpm to be varied according to the load thus reducing consumption and noise.

GSi 3500: 3 kW of maximum power, with a Yanmar 3000 rpm Stage V engine. It is equipped with a double vibration dampening system for extreme silence.

These two products reflect the main features of the range:

• Compliance with anti-pollution regulations combined with excellent performance;

• Advanced control panel for monitoring the main generator parameters with a large display and control buttons for easy reading;

• Soundproof cabin in painted marine aluminum, extremely light and highly resistant to external agents;

• Water-air exchanger that facilitates installation and prevents air exchange with the external environment.

Curious and want to know more?

The brochures of the two products are available by clicking on the following links:

We look forward to welcoming you at our stand 03.544, Hall 3.

To find us follow the directions on the Mets website and for further information please do not hesitate to contact us.

Generating set, which one to choose?

Generators are an indispensable solution for having electrical energy readily available at all times, especially in emergency situations or in places where there is no power source.

Here is a practical guide which includes the main characteristics to consider when choosing the most suitable product for your needs.

1. Rated electrical power

This is measured in Watt and depends on the amount of energy required by the equipment to be powered and its inrush coefficient, i.e. the maximum peak current it can absorb.

The calculation is very simple: the power required must be multiplied by the inrush coefficient, the result is the minimum power of the generator to be purchased.

It is also necessary to assess the type of output voltage of the equipment to be connected, which may be single-phase or three-phase.

2. The engine

Generators with petrol engines are usually space-saving and quiet and deliver up to 12 kW of maximum power. They are an ideal choice in homes, small workshops and on boats.

Diesel-powered generators are more powerful and suitable for long-term and intensive use, are ideal for the construction and industrial sectors.

3. Operating autonomy

It is important to choose a generator with a fuel tank capacity suitable for the type of use and working hours. To obtain more operating autonomy it is possible to opt for models with an increased fuel tank.

4. The noise level

The structure of the next-gen generators is equipped with efficient vibration damping systems and soundproofing panels which, with the same power, make it possible to obtain a lower acoustic impact.

Silenced or super-silenced models are preferred in all environments where noise cannot be tolerated, especially in built-up areas.

5. Mobility

Generating sets can be:

Portable – lightweight and easily transportable.

Mobile – equipped with trolleys and/or handles.

Transportable– can be moved using forklift trucks.

Stationary – designed not to be moved after installation.

For more information, take a look at our wide range of generating sets. Browse through the categories to see the data sheets of each product and do not hesitate to contact us for a tailor-made consultation.

27/10/2021

Why does the hybrid light tower pay off?

Our new LT 5000 SSH-Y and LT 7000 SSH-K hybrid lighting towers have been designed with innovative solutions to reduce their environmental impact.

Quiet and compact, they are smaller and lighter than their non-hybrid equivalents and are ideal as environmentally friendly lighting solution on construction sites, emergency services, events and for use in urban areas.

The battery

The battery of the hybrid lighting towers is in the form of a rechargeable lithium battery, which ensures high-level performance. For instance:

• 9 hours and 15′ of continuous operation, on one hour’s charge, with 4 x 100 W lights.

• 83% reduced maintenance – from 12 to 2 – for 3000 hours of engine operation.

• 64% less expenditure on fuel and therefore on CO2 emissions.

When the battery is flat, the engine recharges it and powers the lamps at the same time. Once the battery is fully charged, the engine switches off automatically.

Safety

The new lighting towers have been designed with low voltage and a permanent magnet alternator (PMG) in order to be used safely even in a hazardous environment, such as the petrochemical industry or mines. The doors allow easy access for all operations, and the wind resistance is 80 km/h when opened.

For more information, take a look at our section dedicated to lighting towers. Browse through the categories to see the data sheets for each product and do not hesitate to contact us for a tailor-made consultation.

25/10/2021

Welding techniques: Shielded Metal Arc Welding (SMAW)

Today we are launching our new monthly column dedicated to welding. It will tell you all you need to know regarding the main accessories, materials and techniques in order to choose the best engine driven welder for your needs. Let’s start with the best known: Shielded Metal Arc Welding (SMAW).

Shielded Metal Arc Welding: what is it?

It is the most common, fastest and cheapest method of welding.

It uses an electrode that is coated with specific materials, which prevents the weld from oxidizing and allows it to stabilize the current arc.

Let’s start with the basics: To begin with, an electrode holder and the material that needs to be welded is connected to the polarities of the welder. The electrode is then attached to the clamp, and when it is brought into contact with the material that needs to be welded, a current arc is produced. In this way, the material that needs to be welded, the coating of the material and the electrode core fuse together.

The different types of electrodes and their electrode coating types:

Acidic (silica, iron silicate): cheap, provides good arc stability.

Cellulosic (cellulose, silicon, manganese): excellent penetration capacity in the material. Suitable for precision work with little slag in the bath.

Rutile (rutile): cheap and easy to store, very smooth welds.

Basic (calcium and magnesium): high purification capacity of the base material, suitable for objects that need to be welded with a greater thickness.

What materials can be arc-welded with a coated electrode?

Almost all materials may be arc-welded, with the exception of lead, zinc, tin, oxygen-reactive and refractory materials.

This process is very versatile but is not recommended for welding joints thicker than 40mm. But we’ll talk about that next time.

In the meantime, follow us on our social to stay updated and find out more in the Engine Driven Welders section, or write to us for a tailor-made consultation.

18/10/2021

New range SS-I

Innovation is our daily mission. Our goal is to offer highly technological solutions to support your business. We are therefore proud to present the new SS-I range.

MG 70 SS-I

MG 110 SS-I

MG 132 SS-I

We wish to develop a long lasting and reliable partnership with you and your company. Our SS-I units have an outstanding performance: durable and noiseless, they are equipped with two silencing devices as well as with soundproof panels. We plan to reduce noise pollution in order to create a better work environment.

Moreover, our units may be applied in several fields such as manufacturing, engineering and emergency.

Our range goes from 66 kVA to 132 kVA in order to offer you the ideal amount of power, which best suits your needs.

The core of our production has always been high quality engines, 4-cylinder FPT with the best power standards; diesel, 1500 rpm. We select our machines’ components with the utmost care to provide you with the best quality production.

But there is no power without control. In fact, each unit includes on-board logic and predisposition for operation in ATS or remote control.

23/09/2021

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Gen Set S.p.A.

Società a socio unico
Via Stazione, 5 - 27030
Villanova d’Ardenghi (PV)
C.F. 10211540157
P.IVA 01470510189