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The War on Error
- Millermatic 251 replaces competitor's complicated pulsed MIG welder
- Simpler interface helps employees who do not speak English as their first language
- Digital meters allow presetting voltage and wire feed speed
- Easy-to-set run-in speed control improves arc starts
Customer Testimonial
“If we don't make a weld correctly... use the right technology or welding processes, we could jeopardize people’s lives. That's why we work very hard to eliminate potential sources of error.”
— Kirk Matheson, Director of Operations, International Armoring Corporation (IAC)
Application
MIG welding of hardened steel plate used for armored, bullet-resistant passenger and special purpose vehicles.
Key Business Issue
Simplify MIG welding equipment and processes.
Challenges
- Replacing a competitor's complicated all-in-one pulsed MIG system.
- Convincing a Detroit auto expert that welds made with conventional MIG processes met mechanical property requirements.
Previous System & Process
A competitor's complicated all-in-one pulsed MIG system and pulsed MIG processes.
New Solution
Millermatic 251 all-in-one MIG welder and conventional MIG processes (spray and/or short circuit transfer).
Results
- Weld quality standard met. Non-destructive and destructive weld testing proved that conventional MIG welding provided the necessary mechanical specifications.
- Easy integration of Millermatics. "We have to keep things simple. If it's not simple and our welders can't make adjustments on the fly, then it kills production efficiency and our ability to deliver cars in a timely manner."
—Ed Fox, plant manager, IAC - Operator acceptance. "The Millermatic 251 was a sound choice for us. It's easy to weld (with) and easy to make adjustments, so we get the best quality weld."
—Tomas Kitian, welder, IAC
Interesting note: The Detroit automotive expert couldn't get the competitor's complex pulsed MIG welding system to work in IAC's application either. - Positive arc starts. Operators can adjust the run-in speed with controls on the front panel (no need to remove the cover). A slower run-in speed eliminated poppy arc starts and associated spatter.
