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All About Metal Fabrication

Welding Types 101: Differences, Benefits, & Applications

Precision welding processes use carefully controlled heat and pressure to reliably fuse metal parts together and create durable joints. Welding is an ideal fabrication technique for assemblies that need inconspicuous weld lines or require close dimensional tolerances. Numerous precision welding methods are available to fulfill the needs of diverse projects, and each type offers its own unique advantages and drawbacks. Read on to learn more about the various types of precision welding, the pros and cons of welding techniques, and common applications.

Different Types of Welding Techniques

Depending on your application’s requirements, you can choose from numerous different types of welding techniques to generate reliable, high-quality welds.

Submerged Arc Welding (SAW)

A highly common welding technique, SAW creates an electrical arc between a workpiece and a continuously fed consumable electrode as well as a flux blanket. Producing welds of exceptional quality while decreasing the likelihood of distortion, this process is compatible with automation solutions, larger projects, and thick metals. However, it necessitates using specialized equipment, requires that you remove post-weld slag, and offers you limited visibility during the process.

Seam Welding

Instead of rods, this welding process utilizes wheels as electrodes to create a continuous seam in your assembly. Seam welding encompasses both friction and resistance seam welding. It’s advantageous for its ability to produce quick yet durable joints with minimal overlapping, heat distortion, and pollution. The process is a good choice for gas- or liquid-tight vessels, but it’s not the right option for metals exceeding 3mm in thickness. The specialized equipment capable of seam welding is also quite costly and requires a highly skilled operator.

Shielded Metal Arc Welding (SMAW)

Called simply arc welding and stick welding as well, the versatile SMAW method generates an electrical arc with a consumable electrode protected by a flux shield. The process doesn’t rely on shielding gas. Equipment for the SMAW technique is both portable and economical, and it’s well-suited to a range of material options as long as they aren’t too thin. However, the SMAW method is slowgoing, and the weld quality relies solely on your operator’s skill. You must also remove slag upon completion.

Gas Metal Arc Welding (GMAW)

Also referred to as metal inert gas (MIG) welding, GMAW shields an electrode of solid wire construction with an external gas supply to safeguard against reactive environmental conditions. Unlike SMAW, this technique is applicable for thinner metals — as long as they’re ferrous —and doesn’t require as high a degree of welding talent to generate welds of superior quality. Another of the advantages of MIG welding is that it allows for faster rates of deposition. With this technique, keep in mind that it does necessitate using a shielding gas, and you might experience wire-feeding complications.

Gas Tungsten Arc Welding (GTAW)

Also known as tungsten inert gas (TIG) welding, this technique protects its non-consumable electrode of tungsten material utilizing an inert shielding gas. The advantages of TIG welding include its ability to create precise, clean, and high-quality welds. Compared to some other welding techniques, it emits less fumes and smoke, and it also works well with a broad spectrum of metals and alloy materials. However, the process is time-intensive and requires a well-trained operator and costly equipment to achieve.

Flux Core Arc Welding (FCAW)

Best for thicker metals, FCAW protects the electrode with core-provided gas rather than external gas like MIG welding. It possesses a higher production factor than GTAW or SMAW methods, and FCAW is beneficial for its high rate of deposition and efficiency. That said, it’s less precise than GTAW and increases your risk of lack of fusion in your project. The process requires shielding gas to work, as well as slag removal post-weld. There are two types of flux core welding: One shielded with an inert gas and one that does not require gas.

Common Welding Applications

The benefits of welding lend it to applications across a wide range of industries, including:

• Aerospace. Precision welding allows operators to generate welds on air- and spacecraft parts, enabling them to achieve tight tolerances for mission-critical components.
• Agriculture. This sector requires rugged equipment, and welded components offer that durability as part of tractors, plows, harvesters, backhoes, balers, sprayers, and more.
• Construction. Precision welding is essential for creating structurally sound welded joints on steel I-beams, support pilings, railings, and general load-bearing components and equipment parts.
• Contract manufacturing. Both manufactured components and manufacturing equipment require precision welding to create lasting, industrial-strength bonds.
• Military. Precision welding is effective at providing assemblies for transport vehicles, trucks, vehicle components, communication tools, process armor kits, submarines, and ships.
• Mining. Examples of fabricated components and welded assemblies for mining equipment include elevators, mine cages and cars, conveyor belts, ore pass chutes, skips, and drifts.

Precision Welding Services From G.E. Mathis Company

G.E. Mathis Company leverages over a century of extensive experience and multi-industry expertise to maximize customer success. At every stage of operations, we maintain the highest level of craftsmanship, product quality, and integrity for even the largest of welding projects. Our company is ISO 9001:2015 and AWS-D1.1 certified, and we have a Certified Welding Inspector (CWI) on our team to ensure consistent weld quality with some of the tightest tolerances in the industry.

Our precision welding processes incorporate computer numerical control (CNC) and automated welding systems for maximum efficiency and accuracy. We work with varied material grades and types ranging from stainless and carbon steel to aluminum and HARDOX^® wearplate, creating lasting welds on products up to 50 feet in length and 12 feet in width.

Along with extensive precision welding techniques, our experienced technicians are fully adept at the following value-added services, which we handle in-house at our fully equipped, state-of-the-art facility:

Offering turnkey service capabilities allows us to meet your expectations for quality products, shorter lead times, and competitive pricing. Contact us to learn more about our precision welding services, or request a quote today to discuss your metalworking needs.

What Is Statistical Process Control?

Statistical Process Control (SPC) is a way of controlling production or processes with the help of certain statistical techniques. With the right statistical control process, you’ll be able to effectively monitor all process activity, proactively identify and address any internal issues, and determine the best methods for fixing them at any point during production.

G.E. Mathis Company implements rigorous SPC tools and procedures to optimize our products and services. We serve companies across a variety of industries, with capabilities like precision laser cutting, plasma cutting, CNC punching, welding, and other custom OEM solutions.

Statistical Process Control

In most cases, statistical process control relies on certain types of control charts, such as the IX-MR and X bar R charts. These charts are prepared in advance for machine operators, who would take measurements of a product characteristic and make measurement entries on the control chart. Using simple math, they plot points and draw lines from one point to the next. In the process, operators would be able to notice any potential issues based on the patterns present, including trends, freaks, and shifts in data.

Once they recognize these patterns, operators can then take the necessary steps to correct any out-of-control conditions present. As a result, processes benefit from improved performance, leading to high-quality output and reduced waste and rejections. The SPC procedure translates to customer satisfaction.

Statistical Process Control Tools

The following statistical tools are the most common ones used in business today:

Statistical Process Control Benefits

SPC offers numerous advantages that make these solutions worth implementing.

Reduced Defects, Waste, and Rework

One of the main benefits of SPC is the development of streamlined processes that make it easier for operators to identify issues and correct them before they can develop into bigger problems. The end result is significantly reduced waste, a lower risk of defects, and the eliminated need for reworks.

Enhanced Product Quality

Another benefit of statistical process control is better product quality, as the SPC tools you use can help spot any problems during production. You can then begin correcting these issues, creating a continuous process that optimizes product quality while preventing shutdowns and downtime.

Elimination of Process Variation

The software and charts you use for the statistical control process will help you determine if there are any process variations to address. You’ll have access to comprehensible data in a graphical format that makes it easy to identify irregular patterns, enabling you to correct them and improve the process.

Compliance With Customer and Regulatory Requirements

SPC software also facilitates compliance with both industry regulations and customer requirements. Businesses can then maintain their operations without concerns over regulatory violations while providing customers with high-quality products that keep them happy.

Reduced, Controlled Expenses

Statistical process control tools help identify and mitigate imperfections in products and processes, helping to minimize the costs associated with rework.

Why Choose G.E. Mathis Company

As a contract manufacturer and job shop that implements SPC procedures, G.E. Mathis Company is committed to delivering high product quality and complete customer satisfaction. With our ISO 9001:2015 certification, we have a fully qualified management system that gives customers much-needed peace of mind. This certification, paired with our SPC tools, ensures we always produce the components you need at the quality and timeline your project requires.

Contact us today to begin your next project with us.

What Is the Production Part Approval Process (PPAP)?

G.E. Mathis Company is in the business of precision. We fabricate and supply high-quality parts, perform machining and contract manufacturing services, and help our clients create innovative solutions. Since our company’s start in 1905, we’ve been a leading provider of more than just manufacturing and fabricating services—we’re also committed to quality control, excellent customer service, and ensuring each part we supply is built to last.

Establishing robust quality control processes is essential to our mission, and Production Part Approval Processes (PPAPs) are a critical aspect of this. A PPAP is a standardized way to communicate about designs and production techniques throughout a manufacturing project in the aerospace or automotive industry. Learn more about the role of PPAPs in the industry, their benefits, and how to get the most value from them during your next manufacturing project.

When Are PPAPs Required?

PPAPs are the final step in a broader Advanced Product Quality Planning (APQP) process. Its core purpose is to ensure parts manufacturers can scale up production to fulfill an order while still maintaining consistency, quality, and adherence to design requirements. PPAPs come in different levels of stringency, and customers can request their own requirements for a successful PPAP. For example, PPAP documents may include a detailed part dimensional inspection report so parts can be mapped to a layout, or they can just set general expectations.

Some of the key information a PPAP document provides includes:

• Details about part approval processes to ensure standard practices are followed
• Processes for approving part changes or method changes
• Required information that will be shared regarding part conformance and related data
• Record of conformance, including measurement of drift
• Design records that can be used to trace part design status throughout the project

While it occurs near the end of the planning process, customers can request a PPAP—and specify the details—early on in the business arrangement, such as in the provided Supplier Quality Assurance Manual (SQAM) or in a purchase order. In terms of the total manufacturing project, PPAPs are required when:

• A change is made to a planned production process
• Parts undergo a change
• A customer requests one (at any time during the product’s lifespan)

PPAP Benefits

Having a production part approval process that is standardized and fully understood by all parties can ensure a project goes smoothly and everyone has appropriate expectations for every stage of the manufacturing process. Key benefits include the following:

• Consistency: Stakeholders can use a standardized part approval process that is well-documented and offers consistency throughout the project.
• Conformity: Customers can be certain that approved parts meet their defined requirements.
• Documentation: Customers have evidence that the process is stable, remains consistent, and will follow established norms throughout production.
• Controlled Approval Process for Changes: Stakeholders can retain control of the process, even if it undergoes changes. PPAPs establish controlled approval mechanisms and channels so no changes threaten nonconformity as the project continues through later production stages.

Levels of a PPAP Submission

PPAPs can be customized to meet unique customer requirements, or they can operate within one of the five standard levels of PPAP submissions. These five levels are:

Level 1

This is a basic level. Submissions include a Part Submission Warranty (PSW) and no other documentation.

Level 2

This level requires a PSW, as well as product samples and some degree of agreed-upon supporting data.

Level 3

At this level, documentation includes a PSW, product samples, and comprehensive supporting data.

Level 4

This level offers more customized requirements. Along with a PSW, customers can set their own requirements for additional data and samples.

Level 5

This is the highest level. Documentation includes a PSW, product samples, and comprehensive supporting data. The information will remain available for stakeholders to review at the manufacturing site.

Manage Higher Quality Processes With G. E. Mathis

Quality control is our top priority at G.E. Mathis Company. Our company is ISO 9001:2015 certified, and we provide the following services to maintain a high level of product quality:

• Capability Studies (Statistical Process Control)
• Conflict Minerals Reporting Template (CMRT)
• First Article Inspection Report (FAIR)
• Production Part Approval Process (PPAP) (all levels available)

Our clients trust our dedication to high-quality manufacturing services and quality control management. Reach out today to learn more about quality assurance processes, metalworking capabilities, and more before starting your next order with us, or request a quote for pricing details.

First Article Inspection Reports 101 – What is FAI / FAIR

Mass production of products within the aerospace and defense industries requires an initial inspection known as the First Article Inspection (FAI) and a report on the results. G.E. Mathis is committed to providing the highest quality inspections and reports that comply with the AS9102 standards to ensure that products meet the correct specifications during manufacturing.

What is First Article Inspection?

At the beginning of a production run, all business quality systems provide a report of the inspection of one to five products straight off the manufacturing line. Regardless of whether the system is certified to ISO 9001, TS16949, or AS9102 standards, quality inspection for compliance with the documentation or customer requirements must be completed before the production run continues. Included in the review are the measurements of the layout to ensure conformity.

Other testing may include material tests and reports, appearance approvals, and more. Once all documents are received, the First Article Inspection Report (FAIR) provides the customer with a review of the product and sets the expectation for the outcome of the full production run. Customers indicate how many parts, between one and five, require inspection in the FAI before approval to continue the run.

First Article Inspection Reports (FAIR)

A First Article Inspection Report (FAIR) can be requested during a mass production run to ensure consistent product quality. However, the FAIR process typically begins by validating the manufacturing processes and the associated equipment, including when:

• Introducing New Parts
• Revising Existing Parts
• New Locations for Manufacturing
• New Supplier of Parts
• Resuming manufacturing after two years

Each FAIR has three forms that must meet the expectations outlined in the documentation. The forms include the part number accountability, product accountability, and characteristic accountability inspection forms. Two forms of inspection are carried out to ensure quality control and product reliability. The first form is dedicated to identifying the part that requires review, along with any sub-assemblies that may affect the quality of the final product. This form helps to ensure that quality issues are identified and resolved at the earliest stages of production.

The second form, product accountability, is a more comprehensive inspection process that covers all related materials, methods, and functional tests demanded by the product design. This form is crucial in ensuring that all product components function correctly and meet the required specifications. By conducting this inspection, any potential defects or issues that may arise during the product’s use can be identified and addressed, resulting in a more reliable and long-lasting product.

Finally, the characteristic accountability inspection ensures that the characteristics, dimensions, tolerances, and aesthetics align with the customer’s specifications. This form includes a detailed drawing or model pinpointing the necessary features identifiable by ballooned or bubbled numbers. A key provides details on the numbered aspects of the picture. The tools used to produce the product are included in the inspection for quality at this time.

Choosing G.E. Mathis Company for Your FAIR

Parts manufacturing is becoming more complex as the parts themselves evolve. Ensuring that each piece manufactured complies with all specified restrictions and requirements is essential to ensure products are successful after assembly. Completing a FAIR inspection during the manufacturing process ensures compliance with regulations and provides clients with product details.

Quality, integrity, and craftsmanship are at the forefront of our values at G.E. Mathis Company. Our dedication to our customers’ success is unwavering, and we strive to uphold these principles in everything we do. In addition to being an ISO 9001:2015-certified manufacturer, G.E. Mathis Company can provide the following services:

• FAIR (First Article Inspection Report)
• PPAP (Production Part Approval Process) – All Levels
• Capability Studies (Statistical Process Control)
• CMRT (Conflict Minerals Reporting Template)

Don’t hesitate to contact us today to learn more about G.E. Mathis Company and how we can apply our metal fabrication capabilities to your next project. Request a quote for your project or FAI assignment and get the expert help your facility deserves.

Our Experience at FABTECH

It’s always a great experience for us to interact with other manufacturers and see what new technologies are trending in the industry. Trade shows and conferences provide us the chance to do just that. This year, G.E. Mathis Company sent a team to attend the FABTECH trade show, which took place in Chicago in November.

At this year’s event, we exhibited, presenting ourselves as a job shop able to fabricate component parts for potential customers. We showcased our various capabilities, which allowed us to show the breadth of work we can handle. It was an exciting show for us, we saw a lot of traffic, and we were able to connect with current customers as well as meet new customers and generate some good leads for future business. We had two of our reps manning the booth at all times, enabling them to answer any questions regarding our capabilities as well as keep a pulse on the industry.

As the show features equipment vendors, fabricators, and businesses that sell services, it is the perfect opportunity for a company like ours to share our capabilities and see what else is happening throughout the industry. For us, it was nice to gain exposure to new people, and we hope to be able to build on the leads we generated. Overall, we thought this year’s show was a success, and we look forward to the industry’s future events. We hope to see you there!

GE Mathis Comapny: Growing Up in 2013

What do we want to achieve in 2013? As the new year gets off to a good start, all of us here at G.E. Mathis Company have reflected on the year that was and are setting future goals. So what do we have in mind?

2012 was a positive year of growth, not just for us, but for manufacturing as a whole. This past year, we have seen an upward growth and we would certainly like to build on that in 2013. Currently, as we are trending upwards, we are slowly returning to a more comfortable manufacturing level—close to a place we held prior to the recession. Our customers have said they are cautiously optimistic about the growth, and we attribute our current success to our wide range of capabilities.

How do we hope to grow ourselves and contribute to the industry? Currently, we are expanding our capabilities, so that we continuously meet the requirements of our customers. As we continue to see positive signs of improvement in the economy, we hope that our capabilities can contribute to this progress. Recently, we invested in new machinery that provides us with unique welding capabilities. After putting this machine into operation, we hope to service a wide range of applications and industries.

What’s one of our biggest goals for 2013? To help contribute to the growth of the economy and manufacturing, and to see industry reach the height it held before the recession. By advancing our capabilities and services, we have high expectations for our business and that of the manufacturing world!

Why we are Celebrating American Manufacturing

Manufacturing. It’s all the rage recently, especially during the month of October—it had been named National Manufacturing Month, in fact. According to a recent article, several national manufacturing associations and departments co-produced National Manufacturing Day (held on October 5th) in order to raise more awareness about manufacturing right here in America. Since companies have been so receptive to the idea, it was decided to extend the awareness for a whole month! Here at G.E. Mathis Company, we understand the importance and value of domestic manufacturing, especially since we are a U.S. manufacturer ourselves. Here are some key reasons why we believe American manufacturing is something to celebrate:

• Economic benefits: The more manufacturing we can do domestically, the less we rely on others and the better state our economy is in. It is economically beneficial for us to export more than we import—the more we can manufacture ourselves, the more solid our economy will be.
• Higher employment: Not only does manufacturing in the U.S provide more jobs and livelihoods for workers, but it creates even further demand for jobs. For example, here at G.E. Mathis Company, we produce components and products that our clients use for their products—therefore, our work is in turn spurring more work once ours is completed.
• Higher quality: We are proud not only to be considered “Made in America,” but also to meet the highest quality standards. Not to mention, if you work with a domestic manufacturer, you have the option to check in on the production process and ensure that the products you are receiving meet your specifications.
• Shorter lead times: With manufacturing being done domestically, the turn-around time is cut down dramatically.

To learn more about American manufacturing, join us in celebrating MFG Day!

A Tradition of Quality Since 1905

Welcome to G.E. Mathis Company and our blog, the space where we plan to open a dialogue with you, our customers, and all those interested in the metal fabrication industry. We enjoy a rich history of quality, integrity, and craftsmanship that began with our great grandfather, a ‘tin knocker’ who opened a sheet metal fabrication shop here in Chicago at the turn of the 20th century. Dedication and hard work earned him a reputation for producing the highest quality fabrications, which, along with superior customer service, sowed the seeds for expansion. The shop went through a transition into the ventilation business, where continuously developing skills and technology led to jobs fabricating heavier steel plate components, which then further transitioned us into the multi-service contract manufacturer that we are today.

With the knowledge and skill passed through the hands of four generations, G.E. Mathis Company has become a nationwide supplier of long, intricate, and close tolerance fabrications. We operate a large, 135,000 sq. ft. facility housed in three separate buildings equipped with some of the largest and most versatile metal fabrication equipment available today, as well as 21 overhead bridge-type cranes for efficient material handling. Advanced production and control technologies allow us to deliver parts with the tightest tolerances in the industry, and our ISO 9001:2015 certified quality assurance program ensures product integrity and customer satisfaction.

Providing a full range of services including laser cutting, plasma cutting, press brake forming, welding and metal finishing, we are excited about furthering our capabilities: we are supplementing our current equipment list with a new large press brake and a submerged arc and MIG welding system at the end of the summer. We hope you take advantage of our expanded offerings in the fall!

Thanks for stopping by to read about G.E. Mathis Company; we hope to see you on these pages again soon. If you would like to learn more about our capabilities, please visit our website, contact us today or request a quote for your next project.