6 Practical Ways to Lower Welding Costs

In steel fabrication, managing costs and improving efficiency are crucial. Welding, being a time-intensive process, plays a significant role in overall production costs. While large fabricators may use robotic welding equipment, smaller and mid-sized operations need practical and cost-effective solutions to reduce expenses without sacrificing quality. Here are six actionable tips to help you achieve this goal:

1. Control Shielding Gas Flow Rates

Shielding gas is crucial for welding, but excessive use inflates costs. High flow rates often cause this issue. Welders should stick to the flow rates specified in the weld procedures. Additionally, investing in technologies that allow for lower flow rates while achieving the same results can lead to substantial savings.

2. Ensure you are choosing the Best Consumables

Welding consumables can account for up to 80% of total welding production costs. While cheaper consumables might seem cost-saving, they often require frequent changeovers, leading to higher long-term expenses. Invest in high-quality consumables that withstand higher temperatures for longer durations to reduce downtime and save both time and money.

3. Follow Design Specifications, do Not Overweld

Using larger welds might seem like a safe bet, but over-welding wastes materials and can weaken the structure by introducing unnecessary heat and causing distortions. Use a fillet weld gauge to follow design specifications precisely. This simple step saves materials and improves the quality of your work.

4. Make Preventative Maintenance a priority

Regular maintenance keeps welding equipment in optimal condition. Scheduling downtime for maintenance might seem counterproductive, but it prevents unexpected breakdowns that halt production and increase labor costs. Preventative maintenance ensures equipment runs smoothly, reducing troubleshooting time and effort.

5. Boost Employee Retention

High turnover rates are costly due to the time and resources spent training new employees. A strong work culture and attractive benefits help retain skilled workers, ensuring your team remains efficient and productive. Investing in employee satisfaction leads to higher productivity and lower training costs.

6. Avoid Unnecessary Weld Consumable Replacements

Consumables like nozzles, diffusers, contact tips, and liners can significantly impact fabrication costs. Some operators replace contact tips after every shift out of routine, without checking if it’s necessary. This practice can waste hundreds, if not thousands, of dollars annually. Not only does it reduce the lifespan of these parts, but it also creates unnecessary downtime for operators.

Operators often change contact tips when facing wire feeding issues or other gas metal arc welding (GMAW) gun problems. However, the root cause is typically an improperly trimmed or installed gun liner. Liners not secured at both ends of the gun can cause issues as the gun cable stretches over time. If contact tips seem to wear out faster than usual, the problem might be due to improper drive roll tension, worn drive rolls, or feeder pathways keyholing.

Proper training on consumable life and changeover can prevent unnecessary replacements, saving both time and money. Conducting time studies in this area can be particularly beneficial. Understanding the expected lifespan of consumables provides welders with a clear idea of when to actually replace them.