SALES & MARKETING                            NEWS                 UPDATE                                      Q3 & Q4 2009...
From the Desk of Martin Quinn                                                                                             ...
Victor products include oxy-fuel cutting and welding     Table of Contentsequipment such as oxy-acetylene and oxy-fuel wel...
WELCOME TO LIFE ON THE EDGEEASY TO USE. ADVANCED DESIGN. UNSURPASSED SAFETY. OUTSTANDING FLOW CONTROL.V   ictor has been t...
It’s easy to use. The Edge Series regulator comeswith gauges with enhanced high contrast graphics.The regulators are color...
PAGE 6 • Thermadyne Sales & Marketing News Update
“THE BEST IN THE   INduSTRY”  As a major equipment supplier to the scrapping industry,  Eddie Grosman knows what it takes ...
3/32"                                                         115 VAC               (2.5mm) MAX                LIFT START ...
True professionals know that nothing can replace a Tweco MIGgun. For decades, welding operators around the world have felt...
VERY COOL, INDEED                                           One of the key features of the Spray Master MIG               ...
“We have experienced a 60-70% increase in totalconsumable life, which has created less downtimewhen changing out parts,” s...
Automation Cut Sample ProgramT   he Thermadyne Automation group has been busy.    The interest in Thermal Dynamics plasma ...
“Thermadyne                                                             FastCut CNC of British Columbia,                  ...
Retrofitting Plasma Systems on Existing CNC SystemsBy John GilbertsonW       ith today’s turbulent times, both industry   ...
TV Coverage Draws Attention toThermal Dynamics CUTMASTER A120T   hermal Dynamics’ CUTMASTER A120 system    received nation...
exceeDINg                                                       expecTATIoNs.                                             ...
The Fundamentals                                           computerized equipment. This advantage suits plasma            ...
due to its erosion effects on welding accessories. The      Helium: Twenty-five percent hotter than argon, heliumextra hea...
bead, thus providing complete penetration through                                                           the thickness ...
Tweco Professional Switchable Magnetic Ground ClampU   niversal style suitable for pipe and plate, the    Tweco Profession...
S     toody is the world leader in the production of welding wires and electrodes used to combat various types of      wea...
Arcair SLICE Pack Delivers Right Combinationof Power and Safety for FirefightersL   ocated about 20 miles northeast of Phi...
In coordination with our distributor Airgas,          “It was great working with Thermadyne and theThermadyne District Bus...
800-426-1888 FAX 800-535-0557www.victorequip.com800-238-0282 FAX 800-535-0557www.turbotorch.com                           ...
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This issue of the Thermadyne Sales and Marketing newsletter contains information about the successful Victor Edge regulators and other products.

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THERMADYNE

  1. 1. SALES & MARKETING NEWS UPDATE Q3 & Q4 2009 NE W P H TING RO IG DU TLLE • SPO C TS • PR O M PP EO OT • ON I S S• PROGRAM
  2. 2. From the Desk of Martin Quinn President Valued Thermadyne Distributors: We hope you will enjoy this issue of our Sales & Marketing News. This publication is dedicated to putting a spotlight on new products, promotions, programs and people. You will note that our cover proudly displays Victor Professional Edge Series regulator which will be launched in September and available for orders in September as well. The product has an advanced design and offers outstanding flow performance. And like everything that is sold under the brand Victor umbrella it was developed with safety as a top priority. Not just Safe. Victor Safe. The Victor Professional Edge Series regulator is an exciting product story, as are a number of other product innovations in the works for our industry leading brands. If you have the opportunity to visit with us at FABTECH AWS in Chicago, we’ll have this and a few other pieces of news to share. We’ll be located in the North Hall at exhibit space 34046. In the meantime, we hope you will not hesitate to contact your Thermadyne representative about Victor, Thermal Dynamics, Stoody, Thermal Arc, Arcair, Tweco or TurboTorch. We are also happy to hear from you via e-mail at marcom@thermadyne.com. Shown here is a rendering of our planned FABTECH AWS exhibit space, which is still in development. The mural backdrop shows a number of metal cutting and welding applications. Under each arch, we’ll showcase a product spotlight area. Video will be running throughout the show with various product features and highlights. Regards, Martin Quinn FABTECH International & AWS Welding Show will be held November 15-18, 2009 at McCormick Place in Chicago. The show will have 1,100 exhibitors and anticipates 35,000 visitors. Event sponsors are: American Welding Society (AWS), Fabricators & Manufacturers Association (FMA), Society of Manufacturing Engineers (SME) and Precision Metalforming Association (PMA).PAGE 2 • Thermadyne Sales & Marketing News Update
  3. 3. Victor products include oxy-fuel cutting and welding Table of Contentsequipment such as oxy-acetylene and oxy-fuel weldingand cutting torch handles, cutting attachments,straight cutting torches, regulators, cutting tips, Victor Professionalwelding nozzles and cutting/welding outfits. Edge Series regulator . . . . . . . . . . . . . . . . . 4-5 Journeyman fan . . . . . . . . . . . . . . . . . . . . . . . . . 6Thermal Arc offers the latest technology in MIGwelding from Fabricator series for light duty to the Bulldog testimonial . . . . . . . . . . . . . . . . . . . . . . 7ArcMaster and PowerMaster inverter technology linesfor industrial Stick, TIG and MIG welding. Thermal Arcis also a leader in plasma welding solutions with a Thermal Arc 95 S Portable DC Welder . . . 8complete line of plasma welding equipment, torchesand consumables. Tweco MIG guns . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tweco Spray Master Case Study . . . .10-11Thermal Dynamics is a pioneer in plasma cuttingsystems. Products include the Thermal DynamicsCUTMASTER True Series manual plasma cutting Thermadyne Automationsystems and a full range of automation products. Cut Sample Program . . . . . . . . . . . . . . . . . . 12 FastCut testimonial . . . . . . . . . . . . . . . . . . . . 13Stoody is a leader in hard-facing technology and highalloy filler metals. Plasma Retrofitting . . . . . . . . . . . . . . . . . . . . . 14 Thermal Dynamics on “Trucks!” . . . . . . . . 15Tweco is a leading supplier of MIG guns andconsumables including the popular Tweco Number4 and Tweco Spray Master MIG guns. Plasma Welding . . . . . . . . . . . . . . . . . . . . .17-19 Stoody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21Arcair is the first name in Arc Gouging. Arcair Slice training . . . . . . . . . . . . . . . . .22-23TurboTorch offers a full line of Air fuel and Oxy fueltorches, equipment and accessories for the plumbingand HVAC market. www.thermadyne.com • Q3 & Q4 2009 • Page 3
  4. 4. WELCOME TO LIFE ON THE EDGEEASY TO USE. ADVANCED DESIGN. UNSURPASSED SAFETY. OUTSTANDING FLOW CONTROL.V ictor has been the leader in gas equipment since its humble beginnings when it was founded on theprinciple of offering only the safest, most reliable and the Victor Professional Edge Series regulator, Victor has breathed new life into gas control technology, giving you more value for your purchase.highest quality gas equipment in the business. WithWARNING: THE GAS INDUSTRY IS COMING UNDER NEW REGULATIONThe new regulation you get with the Victor Professional Edge Series regulator offers outstanding flow control. It’seasy for a regulator to maintain good flow control when inlet pressures are high, but cylinder decay is inevitable.A regulator needs to function well across an entire range of cylinder pressures. That’s exactly where The VictorProfessional Edge Series regulator outperforms the competition.PAGE 4 • Thermadyne Sales & Marketing News Update
  5. 5. It’s easy to use. The Edge Series regulator comeswith gauges with enhanced high contrast graphics.The regulators are color-coded for quick andeasy identification of gas type. They are betterpositioned for hand/body position while adjustingdelivery pressure.The advanced design of the Victor Professional EdgeSeries regulator is the smallest, lightest and mostcompact heavy duty regulator available on the market.The design is innovative and unique and it is a betterregulator from the leading brand in gas equipment.The Victor Professional Edge Series passes all industrystandard tests including the CGA E-4 compliancetesting including the Heated Oxygen Impact Test. It Victor Professional Edge Series regulators are a safemeets or exceeds all requirements of UL 252. It even bet for growing your business too. This is the firstpasses the stringent ASTM G-175 promoted ignition major advancement in gas regulators in one hundredtest. This is a regulator that offers unsurpassed safety. years. The design alone is sure to attract curious buyers. The functionality and performance is sure to lock up sales. Thermadyne has created a broad marketing program to help sales of the Victor Professional Edge Series regulator. The product comes in innovative packaging of durable corrugated construction and a tear away window so customers can view the product while on display. Master pack orders of six (6) regulators for the same gas type are shipped along with a display tray that is ideal for shelves or counter tops.How To Order Pressure Series Type Capacity CGA Gas Type Model Number Part Number (PSIG) Edge SS* 4** 125 540 Oxygen ESS4-125-540 0781-5127 Edge SS* 4** 15 510 Acetylene ESS4-15-510 0781-5132 Edge SS * 4** 15 300 Acetylene ESS4-15-300 0781-5133 Edge SS* 4** 40 510 LPG ESS4-40-510LP 0781-5135 Edge SS * 4** 125 510 LPG ESS4-125-510LP 0781-5136 Edge SS* 4** 125 580 Inert (Nitrogen, Argon, Helium) ESS4-125-580 0781-5143 Edge SS * 4** 200 580 Inert (Nitrogen, Argon, Helium) ESS4-200-580 0781-5144* Single Stage ** High Capacity www.thermadyne.com • Q3 & Q4 2009 • Page 5
  6. 6. PAGE 6 • Thermadyne Sales & Marketing News Update
  7. 7. “THE BEST IN THE INduSTRY” As a major equipment supplier to the scrapping industry, Eddie Grosman knows what it takes to cut through the most rugged materials. So when his customers need help with heavy-duty scrap, he recommends the Victor Bulldog torch. “VICTOR BulldOg TORCHES ARE THE BEST SCRAP TORCHES IN THE INduSTRY,” SAYS EddIE. Along with a great torch, the key to superior cutting performance is the right volume of oxygen supply. “A lot of companies run into problems with portable liquid oxygen bottles and their low output,” he says. Most portable liquid oxygen bottles are limited to approximately 350 cubic ft. of output per hour. “We put an external vaporizer on the bottle to boost the output to roughly 1,000 cubic ft. per hour, and that’s when the Bulldog really tears through anything,” he says. Grosman doesn’t just rely on Bulldog torches to make the tough cuts. They’re also helping his business grow. Eddie’s Welding Equipment is the largest distributor of Victor Bulldog torches in the nation. He says, “We’ve seen consistent growth each month since we began offering Bulldog torches because they are the best.” EddIE gROSmAN Stafford, TX www.eddieswelding.com Eddie carries the torch – will you? THERmAdYNE, A GloBAl cuTTinG And WEldinG lEAdEr, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, metalworking and fabrication. Victor, Thermal dynamics, Thermal Arc, Arcair, Tweco, Stoody, cigweld and TurboTorch are among the Thermadyne family of brands that you can count on for safety, reliability and quality.www.thermadyne.com www.thermadyne.com • Q3 & Q4 2009 • Page 7
  8. 8. 3/32" 115 VAC (2.5mm) MAX LIFT START FAN COOLED THERMAL INPUT POWER STICK WELDING TIG WELDING WARRANTY OVERLOAD Stick Package Part # W1003202 Thermal Arc, a world leader in arc welding technology, presents an incredible welding package with its 95 S. Available in Stick and Stick/TIG packages, it comes with: • Thermal Arc 95 S Inverter welding power source (weighs only 10 pounds) • Tweco® WeldSkill® style electrode holder with 10 (3m) lead • 20 Amp adapter plug & cable • Operating manual • Four (4) general purpose stick electrodes • Operating manual • Easy-to-follow quick set-up DVD The Stick/TIG package comes with all of the above plus: • TIG Torch 17V style 10 (3m) with accessories Stick/TIG Package • Victor® CutSkill® argon regulator/flow gauge Part # W1003203Additional Part NumbersProduct Part No. Description Victor CutSkill Argon Regulator/Flow Gauge 600300 Argon shielding gas regulator with 5/8"-18 UNF hose connection TIG Torch W4012500 17V style TIG torch with 10 (3m) lead, 10 (3m) lead gas hose with 5/8"-18 UNF hose connection, gas valve, 25mm dinse connection and accessory kit W4013300 20 Amp Adapter Plug & CablePAGE 8 • Thermadyne Sales & Marketing News Update
  9. 9. True professionals know that nothing can replace a Tweco MIGgun. For decades, welding operators around the world have feltthe pride of owning one of the most trusted brands in the industry.With a rich history of producing top quality professional guns likethe Spray Master and one of the most popular MIG guns of all time– the No. 4 MIG, it’s easy to see why the Tweco name has becomesynonymous with dependability and reliability. Nothing comparesto the genuine craftsmanship of a Tweco gun. Visit www.twecotrust.com today. www.thermadyne.com • Q3 & Q4 2009 • Page 9
  10. 10. VERY COOL, INDEED One of the key features of the Spray Master MIG gun is how cool it operates in the most demandingSpray Master MIG Guns from TWECO conditions. “The extended trigger on the handle keeps my hand away from the heat of the arc especially when we switch to flux cored wires,” reports Jason Burns, one of DAE’s top welders. The Spray Master handle is designed to stay cool, and can increase overall productivity by not overheating, or creating welder fatigue. It is also designed with a superior Cablehoz rating that can handle higher amperage ranges. This promotes better electrical flow, which reduces the heat that can be generated from poor connections or cable ratings. Consumables such as contact tips are also a main concern when welding in any environment. The Spray Master utilizes super heavy duty contact tips that can support up to 600 amps, and when compared to standard consumables, the parts life can be up to 10 times longer, due in part, by the fact that the Spray Master has extra mass and toughness built into the diffuser and nozzle.L OUISVILLE, KY: DAE Industries, designs, fabricates and installs aircraft engine stands,docking and maintenance access stands, and aircraftmaintenance tooling. DAE has the manpower andexpertise to fulfill nearly any application that requiresaircraft work stands, docks, and engine stands fromengineering and design, construction, installation,modification to relocation.The company has 40 welding and fabrication stations,and was looking for improvements in MIG gundurability and consumable life. The Spray Master MIGGun from Tweco was the answer. Led by ThermadyneDistrict Manager Sean Norton, DAE was able to seeinstant improvements from their existing MIG guns byswitching to the Tweco Spray Master.PAGE 10 • Thermadyne Sales & Marketing News Update
  11. 11. “We have experienced a 60-70% increase in totalconsumable life, which has created less downtimewhen changing out parts,” says Fabrication ManagerDennis Cook. (Dennis Cook is shown in photo on opposite page)“Contact tip life has increased from 2-3 days tonearly 3 weeks,” added Jason Burns, one of DAE’sbest welders.The Spray Master MIG Gun is designed with comfortand feel in mind. It has a natural curved handle thatfits well in most welders hands. Being very lightweight, the Spray Master is also very maneuverable.With a conductor tube that can be rotated 360degrees, and with several conductor tube angles tochoose from, the Spray Master can be configuredfor nearly any application. Jason Burns also notedthat “Tweco has adapted the conductor tubes onour Spray Masters, to create the perfect anglefor welding.”DAE has been using the Spray Master for more than 6months in full time production. It was critical to find asolution that minimized production down time not onlyfrom a welder fatigue and consumable point of view,but from maintenance as well.Dennis also shared that “Spray Master has proven tobe extremely dependable and tough with zero failuresto date, not even a trigger switch. As a matter offact, we haven’t even needed to replace any liners yeteither, the wire keeps feeding extremely smooth.”The Tweco Spray Master MIG Gun was just whatthe doctor ordered for DAE as they considered theirupgrade. It is keeping them running. Congratulationson another Tweco MIG gun conversion success story.A special Thanks to Thermadyne DM, Sean Norton andThermadyne Product Line Manager, Pete Anderson and DAEwelder, Jason Burns and DAE Fabrication Manager, Dennis Cookfor contributing to this story. www.thermadyne.com • Q3 & Q4 2009 • Page 11
  12. 12. Automation Cut Sample ProgramT he Thermadyne Automation group has been busy. The interest in Thermal Dynamics plasma cuttingsystems continues to be of interest to OEM cutting Samples are usually ready within 48 hours on receipt of request. The samplestable manufacturers and integrators. are packaged in“With automation systems being so large, having a professionaldemo units readily available is often impractical. For presentation cutthese instances, cut samples are used to convey sample box andThermal Dynamics’ capabilities to a distributor shipped UPSsalesperson or end user,” says Cutting Product Line Ground along withManager Kent Swart. “Some competitors charge as literature, and amuch as $500 per shipment of such samples but specification sheetThermal Dynamics continues to offer the program free that lists the cuttingof charge.” Here’s how the process works: parameters.Thermadyne Automation sales manager fields the call When end usersand compiles all the pertinent data: request to see their • distributor and end-user contact information exact part cut with an Auto-Cut or Ultra-Cut system, • type of sample required: material type and thickness the process is very similar. A clean DXF file (no • end user expectations, such as: weld-ability, surface dimensions, center lines, etc.) is supplied with the finish, squareness, speed. original request. Custom parts requests are fulfilled within two weeks with turn around dependent onThis data is then given to the samples department the cleanliness of the DXF file and the complexity ofin New Hampshire where the experts determine the the part.optimum specifications to be used to cut the samplesfor the desired outcome. For example, maximizing For more information, contact your localspeed, minimizing kerf/dross, or surface finish. Automation sales representative or e-mail us at: automation@thermadyne.com.Thermadyne Automation specialist John Gilbertson (in black shirt) presents representatives from FastCut CNC of British Columbia, Canadawith special edition framed testimonial ad.PAGE 12 • Thermadyne Sales & Marketing News Update
  13. 13. “Thermadyne FastCut CNC of British Columbia, Canada, built a solid business selling CNC plasma cutting systems to the Automation entry level industrial market. “All of a sudden,” recalls FastCut founder and CEO Brian Gallup, “our resource for brings its A-Game power supplies was having delivery problems. Thermadyne Automation stepped in and saved the day for us.” every day.” FastCut now sells Thermal Dynamics Cutmaster A Series, Auto-Cut and Ultra-Cut plasma systems with FastCut cutting tables depending on the needs of their customers. “Whether it’s a superior cut on gauge material or heavier metal plate, Thermadyne Automation has the answer,” says Partner Carlo Borella. Thermadyne Automation also gets high marks on service. “They work with us. They are open to new ideas. They’re Thermadyne Automation always listening to what we need – no offers a full range of products other supplier comes close. They bring for the metal fabrication industry including plasma cutting their A-Game every day. They invest in from Thermal Dynamics and our customers too with cut samples and robotics from Tweco and instructional DVDs. They’re willing to Thermal Arc. Thermadyne attach their name to ours, which is a big also offers Victor, Arcair advantage for a company like ours.” and Stoody branded equipment and processes. Carlo Borella and Russ Gallupwww.thermadyne.com/automation/thermaldynamicsautomation@thermadyne.com Partners, FastCut CNC, with a G6(866) 279-2628 Fabricator™ and a Thermal Dynamics® Auto-Cut 200 plasma cutter. www.thermadyne.com • Q3 & Q4 2009 • Page 13
  14. 14. Retrofitting Plasma Systems on Existing CNC SystemsBy John GilbertsonW ith today’s turbulent times, both industry businesses and individual welders are lookingfor ways to get more out of the bottom line. One 10. Should Water Mist Secondary be used? 11. What will the air compressor capabilities be in constant pressure and volume?solution is the upkeep, repair and improvement of 12. Most important. What are the expectations? Whatexisting machinery. Rather than replacing a system is the expected outcome of retrofit? Are there specific hole or slot requirements? Where is the businessthat is out of order, many facilities have turned to headed in the short and long term? Example: Todayretrofitting, extending the machine’s life cycle and the job may require ½” but tomorrow it may be tosaving themselves capital expenditures. cut 1½”As retrofitting has become popular, trends for The information above is critical to ensure the correctincreasing parts life has taken hold of the industry, layout of the updated table and compatibility ofincluding retrofitting plasma systems on existing CNC all parts. The worst scenario would be to have the(computer numerically controlled) system tables. In manufacturer go out on location, take everythingthis instance, less is more. By updating CNC tables apart, and then find out the machine doesn’t run fastwith new bearings, Controller and drives, and adding enough or there is a problem with the initial table ora new plasma, end users avoid the high cost of the torch height lifter doesn’t work.purchasing a whole new system. Through retrofitting, In addition to these 12 tips, manufactures also oftennot only is a facility saving a significant amount of utilize a pre-installation checklist. Some questions thismoney, but production and efficiency is increased. checklist may address include:One of the leading global manufacturers and • Does the customer have the proper earth ground?marketers of cutting and welding products and • Does the customer have consumables prior toaccessories, Thermadyne, Inc., offers several tips installation?every customer should know prior to having his CNC • Does the customer have an adequate air compressorSystem retrofitted in order to get the highest-quality and gas supply?and most efficient installation. While the preparation process can be time consuming,1. What is the table’s footprint? the end result is well worth it. Once installation is2. Where does the power source sit in relation to the complete, your system will run more smoothly and entrance of the power track? efficiently. Retrofitting plasma systems on existing3. Is the drive a single or a dual? CNC system tables provides an excellent alternative4. What is the controller on the table, including the serial to those not wanting (or needing) to purchase a whole number of both the controller and table? new system. If you are still unsure if retrofitting is the5. What is the torch height lifter, including the serial right decision for your system, manufacturers and number? installers can provide expertise to help determine the6. Does it have a power track (Single or Dual) or a best route to meet your production needs. Festoon?7. What material thickness and types of material are to John Gilbertson is an Automation Manager for be cut? Thermadyne, Inc. He can be reached at8. What is the input power and breaker size? 720-320-9336 or jgilbertson@thermadyne.com.9. What gas will be used to cut with (Water Mist Secondary, Oxygen, Nitrogen, Hydrogen-35, or Air)?PAGE 14 • Thermadyne Sales & Marketing News Update
  15. 15. TV Coverage Draws Attention toThermal Dynamics CUTMASTER A120T hermal Dynamics’ CUTMASTER A120 system received national media coverage recently whenThermadyne Automation partner TorchMate, one of Additionally, the A-Series system features: • A powerful 80% Duty Cycle to handle all-day production cutting in the toughest environmentsthe top automation distributors, was featured on an • Light-weight, compact design and convenient mountingepisode of Spike TV’s, “Trucks!” feet which allow for easy mounting in any application “Trucks!” which airs every Sunday, highlights • Valve in torch design, reducing cycle time between parts and increasing productivityautomotive mechanics involving trucks and SUV’s, • CNC Interface connection located on the rear ofranging from improvement, to customizing, to creative the power supply offering “Start/Stop” and “OK toworks. In every episode the show includes segments MOVE” signalspertaining to the history of those involved with racing • Full arc voltage using an internal terminal connectionand/or customizing trucks –often including a “How It • Software that automatically detects the torch thatWorks” section. is attached and switches between automation andOn the March 29 episode, “Trucks!” workers installed manual modesa Thermal Dynamic’s A120 system and an air scribe • Dedicated automation software, improving cycle timeonto a TorchMate table, not only highlighting the and performanceinstallation, but the system’s operation. With all the advantages of 1Torch and proven CUTMASTER reliability, the new automatedPart of the next generation of Automated CUTMASTER CUTMASTER A-Series delivers the best inSystems from Thermal Dynamics and based on the productivity, precision and performance onsame platform as the TRUE Series, the CUTMASTER the market.A-Series offers standard features to meet the needs ofautomated applications.The A-Series includes the SL100 SV 1Torch withstandard ATC Quick Disconnect in lengths of 25 ft.,35 ft., and 50 ft. The 1Torch start technologyeliminates the electronic interference that can occurwith other designs and provides quick, reliable startsand a strong pilot arc to pierce heavy plate. Torchmate vehicle proudly displays Thermadyne brands and Thermadyne Automation logos. www.thermadyne.com • Q3 & Q4 2009 • Page 15
  16. 16. exceeDINg expecTATIoNs. Kyle is a self-employed welder and owner of K&K Welding in Berlin, MA. He finds that free time is difficult to come by. That’s likely because Kyle works primarily with aluminum. “You can pick up steel welding pretty fast,” he says. “But aluminum is a whole different animal. If you can weld aluminum, it opens up a lot more doors.” With his skill in such high demand, Kyle needs flexible equipment that he can rely on to get the job done. That’s why he loves his Thermal Arc Inverter Arc Welder. “When the Thermadyne representative came to my door with this little machine, I thought there was no way it could do what I need it to,” he said. The power and flexibility of the Thermal Arc Inverter Arc Welder shocked him. “I welded a 4’x4’ aluminum plate, 2” thick with 4 gussets onto a plate that was 1½” thick with minimal preheat,” he says. “Now I’m asking ‘what can’t this little machine do?” Kyle ZIegler K&K Welding Berlin, MA Kyle carries the torch – will you? THerMADyNe, A gloBAl cuTTIng And WeldIng leAder, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, metalworking and fabrication. Victor, Thermal dynamics, Thermal Arc, Arcair, Tweco, Stoody, cigweld and TurboTorch are among the Thermadyne family of brands that you can count on for safety, reliability and quality. www.thermadyne.comPAGE 16 • Thermadyne Sales & Marketing News Update
  17. 17. The Fundamentals computerized equipment. This advantage suits plasma welding for automation purposes in which high-volume and repeatable short duration welds are needed.of Plasma Welding The Energy Source of Plasma Welding The plasma gas serves as the energy source duringBy Gary Reid plasma welding, plasma gases go through the torch,F or those who choose a vocation in plasma welding, learning and practicing the fundamentals of thetrade never stops. A dangerous profession, welding around the electrode and through the orifice. Plasma gases include argon or argon hydrogen, but pure argon is by far the most commonly used, followed byrequires strict adherence to safety protocols and argon hydrogen.continuing education throughout one’s career. So forthose who need a refresher course, let’s get back to Argon: Utilized 98 percent of the time for plasmathe basics. welding, argon breaks down and creates a plasma stream easier than any other gas. Thus providing theThere are three states of matter – solid, liquid and gas best pilot arc and feather at the end of the torch for– right? Wrong. Your sixth grade science teacher didn’t starting the welding arc. Additionally, argon is an inerttell you the whole truth. Consider the fourth state of gas, which means it does not contaminate or oxidizematter, plasma.... the base materials.Plasma welding is a super heating of gas that Argon Hydrogen: Consisting of 98 percent argon and 2becomes highly conductive and in welding allows for percent hydrogen. This mixture is only recommendedthe transfer of an electric arc. When you pass a gas for nickel base materials such as stainless steel. Thethrough this electric arc, it breaks the gas down and hydrogen content in argon produces a hotter arc andforms what is called a plasma stream. Plasma streams breaks up the surface oxides on the material beingcan be seen throughout our atmosphere in several welded and also stabilizes the weld puddle. However,common forms. For instance, lightning is caused by this gas is seldom used for the plasma, except in thean electrical charge passing through the atmosphere case of welding thin materials at low amperage levels,breaking down the atmospheric gases.Getting back to the significance of the basics, becausetemperatures of a plasma flame can reach as highas 30,000 degrees Fahrenheit, safety is always ofutmost importance. By understanding the purposeand choices in plasma welding, professionals willhave a clear guideline to the proper operation andapplications for the trade.Plasma Welding Then and NowDr. R. M. Gage is credited with the introduction ofplasma into the welding industry in 1955, and inthe 1960s, it integrated into micro-plasma and highcurrent applications. Today’s process has grown andis primarily used in welding automation applicationsapproximately 80-85 percent of the time.Similar in process to GTAW or TIG welding, plasmawelding offers the added benefit of not using highfrequency for arc start, which can interfere with www.thermadyne.com • Q3 & Q4 2009 • Page 17
  18. 18. due to its erosion effects on welding accessories. The Helium: Twenty-five percent hotter than argon, heliumextra heat produced by the hydrogen significantly is used for the welding of aluminum, copper andshortens the life of the plasma tip. copper alloys, and thick titanium. In these materials, heat is conducted throughout the metal very quickly.The shielding gas flows on the outside of the tip and Helium’s extra heat provides an advantage ininside of the shielding cup. This protects the weld producing heat for the weld puddle faster than it ispuddle from the atmosphere and ensures the weld being transferred away. However, since it is lighterpuddle does not oxidize. Argon is also the most than air, helium floats away more rapidly and maycommonly used gas for shielding, followed by argon require a gas trailer on the torch to ensure the shieldhydrogen and helium. gas stays over the weld puddle long enough for theArgon: Argon is the cheapest gas to use, it is heavier weld puddle to cool.then air thus providing good shielding of the weld Modes of Operationspuddle, and also provides good arc stability. It also In plasma welding there are three different modesallows for the best and longest pilot arc feather for the of operation which are determined based on thepilot arc. The better the feather the better the welding current, plasma gas flow rate and orifice diameter.arc will transfer to the part to be welded. These are micro-plasma mode, high-current mode andArgon Hydrogen: Used for stainless steels and nickel- keyhole mode.based alloys. By creating a hotter arc and in turn a Micro-Plasma Mode: Ranging from .1 to 15 amps,hotter puddle, it will narrow the weld bead and drive allows the welder to operate with a longer arc lengththe penetration down in the base material reducing in relation to GTAW removing the possibility ofsurface tension of the puddle and allowing the touching the electrode to the work. At low weldingincrease of travel speed. In addition, it has a tendency current levels, the arc remains stable making itto break up the surface oxides on the puddle, creating suitable for welding very thin materials in delicatea more stable puddle and smoother flow.PAGE 18 • Thermadyne Sales & Marketing News Update
  19. 19. bead, thus providing complete penetration through the thickness of the part in one pass. On very thick material a joint design will be needed to reduce the thickness of the material, and multi passes in the non- keyhole mode will be needed to fill the joint. Conclusion Plasma Welding sustained success will be determined by the diligence of its professionals to adhere to best guidelines for usage and safety protocols. We have recently seen its outstanding versatility, quality and control mainstream the application into a variety of industries including aerospace, automobile and railway repair operations. Welders always have choices during application, but recognizing the fundamentals and understanding a tool’s purpose will truly guide anysituations. The micro-plasma mode can be used for professional to the perfect weld.tool and die, and mold repair. Gary Reid is a retired Plasma Welding ApplicationsHigh-Current Mode: Also known as melt-in-mode, Technician for Thermal Arc, a world leader in arctypically ranges from 15 to 400 amps and is used for welding technology. Gary can be contacted by e-mailprecision and high-level weld quality operations and at marcom@thermadyne.comalso overlay applications such as hard surfacing. With Problem Free Torch Set-Upa protected electrode inside the torch, it improves The following the seven tips below will help ensure a problemgood welding geometry and penetration control. free torch set-up for every weld.This mode provides a reliable arc transfer and arc 1. Pre-purging before starting the pilot arc is essential to long torch life, also turning the pilot arc off first and allowing thestability. However, this technique can only be used in torch to purge before turning the machine off is essential to keep the hot electrode from oxidizing.conjunction with larger orifices and precise plasma 2. Always check that the gas distributor is installed correctly.gas flow rates control to avoid burning out the plasma 3. Be sure the correct tip and tungsten for amperage aretip. There are two ways to set the tungsten in the selected.torch in this mode. In most cases the electrode can 4. Remember maximum amperage rating is achieved using a flush tungsten setting.be set flush with the end of the tip. This will give you 5. Set plasma gas as high as possible without disturbing thea soft arc much like a GTAW arc. The second way puddle. This will deter the tip of the torch from being starvedis to recess the tungsten inside the plasma tip, this of plasma gas and burning the tip out quicker. 6. When installing parts confirm they are not contaminated withcan vary in distance not to exceed the recommended body oils or soiled surfaces.setting in the book. By recessing the tip you will get a 7. Periodically evaluate the condition of the ground clampingmore column type arc. surface to avoid losing amperage.Keyhole Mode: Ranging from 100 amps and aboveand is produced by using the recess tungsten in thetip and increasing the current level and plasma gasflow. This type of mode generates a powerful plasmaarc, very similar to a laser beam. During welding, theplasma arc pierces through the material producinga keyhole through the part, with the molten weldpool flowing around the keyhole to form the weld www.thermadyne.com • Q3 & Q4 2009 • Page 19
  20. 20. Tweco Professional Switchable Magnetic Ground ClampU niversal style suitable for pipe and plate, the Tweco Professional® Switchable MagneticGround Clamp design incorporates a V-channel which Improvements in design, configuration and materials deliver lighter weight, greater clamping ability, less cost and more durability. Clamps come in three sizes,accommodates an attachment to pipe and plate in designed to handle up to 200 amps, up to 300 ampsone magnet, with an easy connect, easy release knob. or up to 600 amps.Hardfacing and High Alloy Product Selection GuideI ncludes latest alloys, product descriptions with part numbers, application photos that demonstrate thevaried potential uses for the products. The Guideis divided into easy-to-read sections dealing withCoated Electrodes and Bare Rods, Open-Arc and Gas-Shielded Wires, Submerged Arc Wires, and High AlloyJoining and Cladding. Topics such as metal to metalwear, metal to earth for moderate to severe impactand moderate to severe abrasion, metal to earthfor extreme abrasion and low impact, and abrasionaccompanied by corrosion and/or high temperaturesare all covered.Ask your Thermadyne representative for a copy of thishelpful Stoody Guide.PAGE 20 • Thermadyne Sales & Marketing News Update
  21. 21. S toody is the world leader in the production of welding wires and electrodes used to combat various types of wear and corrosion. Industries as diverse as construction, mining, oil and gas, energy, steel and recycling havecome to depend on Stoody. Contact your Thermadyne representative about quality solutions in hardfacing, wirefiller metals, welding alloys, arc wire, arc flux and electrodes from Stoody.Earth Moving - Construction Power Plants Applications Mode - Wear or Repair Product Process Applications Mode - Wear or Repair Product Process Idler Rolls Metal to Metal ThermaClad 42 SAW Roll Crushers/Coal Low Impact & Abrasion Stoody 100HD / CP2000 / 103CP FCAW, SAW Track Rollers, Metal to Metal Stoody 105B SAW Grinding Rings/Coal Low Impact & Abrasion Stoody 100HD / CP2000 FCAW, SAW Rails & Sprockets Metal to Metal Super Build Up GMAW, FCAW Rotary Vane Wheels High Abrasion CP2000 / Stoody 160 / Vancar FCAW, SMAW Sprockets & Gear Teeth Metal to Metal Stoody 1105 SMAW Mill Liner Plates High Abrasion CP2000 / WP2000 FCAW, SMAW Ripper Shanks Moderate Impact & Abrasion Stoody 101HC FCAW Clinker Grinders High Abrasion Stoody 600 FCAW, SMAW Dozer Teeth Moderate Impact & Abrasion Stoody 31 / Stoody 600 SMAW, GMAW Elbows and Veins Low Impact & Abrasion Stoody 35 SMAW Low Impact & High Abrasion Stoody 35 SMAW Steam Valves High Temperature, Metal to Metal Stoodite 21 & 6 OAW, GTAW, SMAW, FCAW Low Impact & High Abrasion Stoody 101HC GMAW, FCAW Low Impact & Severe Abrasion Borium (ATB) OAW Low Impact & Severe Abrasion Vancar OAW, SMAW, FCAW Dredging Low Impact & Severe Abrasion Stoody 130 / 160 FCAW Bucket Lips & Teeth Moderate Impact & Abrasion Stoody 31/Stoody 35 SMAW Applications Mode - Wear or Repair Product Process Pump Housings Low Impact & Abrasion Stoody 100HD CP2000 / WP2000 FCAW High Impact Stoody 117 FCAWQuarries - Crushing Pump Sheals & Impellers Moderate Impact & Abrasion Stoody 117 FCAW Rotary Cutter Teeth High Stress Abrasion Stoody 160 FCAW, SMAW Applications Mode - Wear or Repair Product Process Roll Crusher-Rollers Build Up/Repairs Roll Crusher Stoody 2110 / 110 SMAW / FCAW Build Up & HardFace Roll Crushers Stoody 117 FCAW Agriculture Rotors & Impeller Bars Build Up / Manganese / Carbon Steel Stoody 2110 / 110 SMAW / FCAW Crusher Hammers Moderate Impact & Abrasion Stoody 2134 SMAW Applications Mode - Wear or Repair Product Process Jaw Crusher - Jaws Moderate Impact & Abrasion Stoody 134 FCAW Sweeps Moderate Impact & Abrasion Stoody BTS OAW High Impact & Abrasion Stoody 600 FCAW Moderate Impact & Abrasion Stoody 31 FCAW Joining Joining Manganese to Carbon Steel Stoody 2110 / 110 SMAW, FCAW, GMAW Low Impact & Abrasion VanCar OAW, SMAW, FCAW Various Hammers Low Impact & High Abrasion VanCar SMAW, FCAW, GMAW Chisel Points Moderate Impact & Abrasion 965G SMAW, FCAW Worn Cones & Mantles Repairs Stoody 110 / 2110 SMAW, GMAW , FCAW Ammonia Injector Feet Low Impact & Abrasion Borium (ATB) / VanCar OAW, SMAW, FCAW Build Up & HardFace Stoody 117 FCAW Mill Hammers Medium Impact & Abrasion Borium (ATB) (TB-2954) OAW New Cones & Mantles Moderate Impact & High Abrasion Stoody 100 HC FCAW Oil - PetroleumMining Applications Mode - Wear or Repair Product Process Applications Mode - Wear or Repair Product Process Tool Joints Medium Impact & Abrasion ThermaClad 104TJ SAWDragline Bucket/Shovel Tips High Stress Abrasion CP2000/Stoody 160 FCAW Hardbanding Medium Impact & Abrasion CP2000, Stoody 600, Stoody 100 FCAW Tunneling/Boring Low Impact & Severe Abrasion Stoody VanCar 130 FCAW Valve Trim Corrosion & Abrasion Stoodite 6 OAW, SMAW, GMAW, SAW Conveyor Pipes High Abrasion CP2000/Stoody 160 FCAW Rock Bits (Shirt Sleeves) High Stress Abrasion ATB-Acetylene Tube Borium-(H-Rod) OAW Augers High Abrasion Stoody 101HC/CP2000/160 FCAW, SMAW High Abrasion Super 20 FCAW, SMAW Cable Sheaves Metal To Metal ThermaClad 42/102/1102 SAW, GMAW, SMAW Steel Mills Dragline Pins Metal To Metal Stoody 102 SMAW, FCAW, SAW Applications Mode - Wear or Repair Product Process Rolls Temperature & Abrasion ThermaClad Alloys SAWCement Applications Mode - Wear or Repair Product Process LoggingPulverizing Mill Raw Material Moderate Impact & High Abrasion Stoody 100HC FCAW Applications Mode - Wear or Repair Product Process Moderate Impact & High Abrasion Stoody CP2000 or 2001 FCAW Debarking Hammers Medium Impact & Abrasion VanCar OAW, SMAW, FCAW Pulverizing Rolls & Tables Low Impact & High Abrasion Stoody CP2000 FCAW Feed Screw Flights High Abrasion Stoody CP2000 / 130 / 160 FCAW High Pressure Clinker Rolls High Pressure & Abrasion Stoody 600 FCAW Recycling Build Up ThermaClad Roll Build 3 SAW Applications Mode - Wear or Repair Product Process Mill Paddles Moderate Impact & Abrasion Stoody 35 SMAW Tire Shredding Knives High Stress, Metal to Metal Stoody M7 FCAW Tube Grinders High Stress Abrasion VanCar OAW, SMAW, FCAW Rotor Disc Car Crusher High Impact Stoody 110 SMAW, FCAW www.thermadyne.com • Q3 & Q4 2009 • Page 21
  22. 22. Arcair SLICE Pack Delivers Right Combinationof Power and Safety for FirefightersL ocated about 20 miles northeast of Philadelphia, the Borough of Bristol is the home of whatis believed to be the second oldest fire house in “We have had a torch on one of our fire trucks for many years,” said Bristol Fire Company Chief Herb Slack. “The first torch we had was an acetylene/continuous use in the U.S. The 30 volunteer members oxygen torch. Later we changed to MAPP gas. Whileof the Bristol Fire Company have roots in history we felt that we needed to have a torch available, webut enthusiastically embrace the latest technology were always concerned about having a cylinder ofto respond to approximately 300 annual calls for flammable gas stored in the compartment on the fireassistance with fires, rescues, hazardous material truck. In addition to the safety issues, the torch setincidents and emergency medical calls. up and use was often difficult for the average member because the need for the torch was infrequent. WeMembers spend hundreds of hours of training in find that the SLICE is easier to set up and use, cutsfirefighting, hazardous materials, medical emergencies more materials faster than the fuel gas/oxygen torchesand all types of rescues including vehicle accidents, and is safer because we are no longer carrying aconfined space, industrial accidents, trench and cylinder of flammable gas on the fire truck. Thankselevator rescues. Through an Assistance to Firefighters to the AFG program, we have a SLICE torch on eachGrant (AFG) from the Federal government, the fire truck. We believe that the torches and the trainingCompany recently purchased the Arcair® SLICE® Pack, improve our operational capabilities to better servea cutting system that is used predominantly for forced our community.”entry or victim extrication.PAGE 22 • Thermadyne Sales & Marketing News Update
  23. 23. In coordination with our distributor Airgas, “It was great working with Thermadyne and theThermadyne District Business Manager Jim Henry Bristol Fire Company,” said Gina DeMario, Airgastrained the Bristol Fire Company crew on the SLICE, Business-to-Business Associate who, with Bristoland demonstrated the components of the torch, Fire Company Chief Deputy Fran Hufnell, set upproper care, set up, the importance of safety and the training. “Everyone was very pleased and veryactual use of the torch. engaged throughout the entire presentation. It was quite impressive.” www.thermadyne.com • Q3 & Q4 2009 • Page 23
  24. 24. 800-426-1888 FAX 800-535-0557www.victorequip.com800-238-0282 FAX 800-535-0557www.turbotorch.com Pictured above are “Doc” Oliver of Three800-569-0547 FAX 800-535-0557 Mules Welding Supply, and Thermadynewww.victorequip.com District Manager John Abbitt, at the Potomac Speedway in Mechanicsville, Md ., in front of one of the Three Mules- sponsored dirt track racecars . Jimmy Oliver, who along with his father “Doc” and brother Brian, owns Three Mules, says many of Thermal Arc’s welding800-426-1888 FAX 800-535-0557 products are used to make theirwww.tweco.com customized cars race ready . “Getting involved in building800-426-1888 FAX 800-535-0557www.tweco.com and racing these cars has been good for business,” said Jimmy. “Racers from several states have come800-382-8187 FAX 800-535-0557 to our stores to ask uswww.victormed.com about our work and buy our equipment.” Three Mules has stores both800-426-1888 FAX 800-535-0557 in Mechanicsville andwww.thermal-dynamics.com Lexington Park, Md.800-426-1888 FAX 800-535-0557www.thermalarc.com800-426-1888 FAX 800-535-0557www.stoody.com866-279-2628 FAX 800-535-0557www.stoody.com Q3 & Q4 2009 Sales & Marketing News

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