Shipbuilding

ITW Welding

WELDING SOLUTIONS
 Set a Course for Greater Shipyard Productivity
We understand that shipbuilding is a competitive Trusted partnership
business with a variety of welding challenges. Your goals are our goals. Your success is our
That’s why we’ve developed efficient, ship- success. We are your trusted partner who stands
specific solutions to achieve higher-quality welds ready to help you achieve your welding and
fabrication objectives.
throughout the shipyard. Our integrated welding
systems and filler metals allow us to provide our Cost reduction
customers with several vital benefits, including: In today’s market, cost containment is
essential for long-term success. Our people and
Greater productivity
products will help you reduce costs and remain
Leveraging your investment in people and
competitive.
equipment is one key to sustaining success.
From bow to stern, we have the right solution
Innovation
to make all your shipbuilding applications more
At the core of all of our products is innovation.
efficient and more productive.
Our designs deliver tangible benefits not found
in competing products. We pride ourselves on
developing easy-to-use welding solutions that allow
you to maximize productivity, quality and safety,
producing a superior ship for your customer.

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Outstanding support
Our unrivaled customer service enables us to support you
in your shipbuilding goals.

Safety
Our products help you create a safe work environment, from
Countless capabilities.
personal protective equipment to weld fume extraction. Trusted advice.
Integrated solutions.
Total welding solution
With our power sources, filler metals, guns and fume Shipbuilders place their trust in the
extraction products working together through innovative ITW Welding companies for reliable
technology, the result is a total welding solution from a solutions that produce higher-quality
single source you can rely on. welds and improve productivity.
Miller, Hobart Brothers, Bernard
and Weldcraft all work together to
create a comprehensive welding
solution. Premium MAXAL® filler
metal completes our total aluminum
welding offering. Whatever your
welding needs in shipbuilding,
look to ITW Welding companies.
Together, we’ll develop world-class,
integrated solutions to help you
achieve your goals.

ITW Welding

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 Hull
Innovations in Welding
for Improved Productivity
Our industry-leading technology and shipbuilding expertise will give you the edge you need in hull production.
Induction heating will help you achieve code-quality welds faster and more consistently. Miller-exclusive
products, including our Weld Cable Control System and AlumaFeed™ Synergic MIG System, can help you
optimize weld quality, boost your welding productivity and upgrade worker safety in hull applications.

Weld Cable Control (WCC) System

Exclusive Miller® technology in the Weld Cable Control System uses the weld WCC System options
cables to communicate changes in voltage settings. In the WCC System,
voltage and wire-feed-speed controls are conveniently located at the
operator’s fingertips — right at the point of use — not back at the power
source. By eliminating control cables to the feeder, cabling is streamlined
and operators work at maximum efficiency.

Increased productivity
• No time-consuming trips to the power source because operators
can easily set optimal welding parameters at the point of use. Remote
voltage control extends your reach beyond control cable systems and Multiprocess XMT® 450 and
results in more arc-on time. XMT® 350 WCC Welding System

Improved weld quality

• Reduces costly “work arounds” — Operators can easily adjust to
optimal welding parameters without leaving the work area. This allows
for improved quality caused by improper parameter selection.

Improved worker safety

• Reduce operator hazards and injuries — Operators don’t have to
climb ladders or move through manways to make voltage adjustments.
They can set welding parameters right at the point of use, greatly
reducing the risk of trip and fall injuries.
Multiprocess Dimension™
Maximum efficiency and durability NT 450 WCC Welding System

• Reduced costs — Eliminating control cables to the feeder reduces

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costly cord setup/maintenance/repair costs.
 Hull Welding Solutions
AlumaFeed Synergic Aluminum Welding System
™

Aluminum is an increasingly popular choice for ships of all sizes. Because

it is lightweight, corrosion-resistant and affordable, aluminum allows ships
to travel faster and carry bigger payloads over a longer range. The unique
characteristics of aluminum have always presented welding challenges.
However, the Miller AlumaFeed Welding System simplifies and improves
MIG and Pulsed MIG aluminum welding for shipyard applications.
With the AlumaFeed system, your operators work with consistent arc
quality and superior puddle control to produce professional, code-quality
welds every time.
• Long, linear welds can be accomplished using the feeder’s remote start
option when connected to various weld positioners.
• Get the stacked-dime TIG appearance with the production speeds of
MIG, thanks to Profile Pulse™ technology.
• Reduced burn through and distortion — One-knob synergic welding control sets
the correct Pulsed MIG parameters based on the wire feed speed set by the operator.
• Improved portability — The AlumaFeed wire feeder is ideal for going up stairs,
through portholes or mounting on booms to reach every corner of the work area.

MaxalMIG®Aluminum Wire
A premium filler metal solution, MaxalMIG wire provides options for 5183, 5356,
5554 and 5556 alloys that offer several advantages for consistent aluminum welding
performance:
• Superior arc starts and stability.
• Extreme cleanliness — Able to exceed the AWS porosity standard.
• Outstanding feedability.
• Excellent welder appeal for repeatability and consistency.

ProHeat™ 35 Induction Heating System

Induction heating offers many key advantages for shipbuilders using
high-strength steels such as HY-80, HY-100 and BH-36 to reduce weight.
Unlike other methods of heating, the ProHeat has the ability to control
heating rates as well as desired target temperatures during the weld
process. As a result, the joint achieves the required strength and Shown with
hardness, and it’s easier to meet the strict preheat and interpass optional recorder
standards dictated by AWS and ABS. and cooler

• Faster cycle times — Induction heating brings the steel to

temperature in minutes rather than hours — far faster than with
propane or resistance heating.
• Maintains the desired temperature without having to stop
welding to add more heat.
• Provides uniform heating.
• Safe and cost efficient — Eliminate operator exposure to open flames,
explosive gases and hot heating elements involved with other methods. For more details on ProHeat
35 Induction Heating, contact
Reduced labor time, less rework and lower gas usage saves operating costs.
Miller Pipe Welding Products
• Better weld quality — Welds consistently achieve required strength at 920-735-4001 or email
and hardness, minimizing the risk of hydrogen cracking. pwpservice@MillerWelds com.

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 CST™ 280
The CST 280 is extra-versatile and durable, yet weighs just 41 pounds. With its
dual process capability and easy portability, this compact Stick and TIG power source
is ideal for pipe and plate work in shipyards.
• Superior Stick performance, even on difficult-to-run electrodes.
• Includes Lift-Arc™ technology to improve TIG arc starts.

Hobart Brothers Filler Metals

Hobart Brothers offers a wide selection of filler metals, including flux-cored wires, submerged
arc electrodes and stick electrodes to meet the demands of shipbuilding applications, while
also enhancing quality and improving productivity. Attributes include low hydrogen levels to
help prevent cracking, excellent impact strengths at low temperatures, x-ray-quality welds
and consistent gap bridging.
• Hobart® Excel Arc 71™ gas-shielded flux-cored wire
This high penetrating, all-position wire provides a low-hydrogen weld
deposit to minimize instances of cracking or other weld defects. Designed
for 100 percent CO2 or 75 percent argon/25 percent CO2 shielding
gas mixture.
• Tri-Mark
 ® Triple 7 gas-shielded flux-cored wire
With a fast-freezing slag that is easy to remove, this wire permits
the welder to use higher current to deposit more metal faster and
still produce an x-ray-quality, flat bead in all welding positions. Designed for 100 percent
CO2 or 75 percent argon/25 percent CO2 shielding gas mixture.
• Tri-Mark
 TM-771 gas-shielded flux-cored wire (QPL*)
Designed for use with 100 percent CO2 shielding gas, this wire improves out-of-position
welding and provides excellent impact values.
• Tri-Mark TM-770 gas-shielded flux-cored wire (QPL*)
Gain superior weldability, outstanding mechanical properties and consistent performance
with this wire designed for 75-85 percent argon/15-25 percent CO2 shielding gas mixture.
• T ri-Mark TM-71 HYN gas-shielded flux-cored wire (QPL*)
Designed for welding HSLA-65 grade steel, this wire exceeds the stringent welding
standards established by the U.S. Navy and offers x-ray-quality welds. Designed for
75 percent argon/25 percent CO2 shielding gas mixture.
• Hobart FabCO® 81K2-C gas-shielded flux-cored wire
Characterized by a smooth, stable arc and low spatter levels, this low-alloy wire is an
excellent choice for out-of-position applications. Designed for 100 percent CO2 shielding gas.
• T ri-Mark Metalloy® EM13K-S metal-cored submerged arc electrode
with HN 590 Flux
Combined, this metal-cored wire and flux produce weld deposits with good mechanical
properties and consistent bead tie-in, and can weld through mill scale and rust
without porosity.
• Hobart 718MC stick electrode (QPL**)
This stick electrode is designed to improve deposition rates and bead appearance
on applications requiring low-temperature impacts.

Qualified Products List (QPL)

Qualified under Military Specification MIL-E24403/1
*

Qualified under Military Specification MIL-E22200/10C

**

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 Pipe Welding Solutions
Pipe
Solutions That Match Your Demands
for Speed and Weld Quality
Our innovative welding solutions for pipe fabrication can save setup time and reduce your production costs.
For plate work, pipefitting and welding under challenging shipyard environments, Miller® provides power sources
that improve productivity and weld quality while lowering operating costs.

PipeWorx™ 400 Welding System

Simplified and optimized specifically for pipe welding, the PipeWorx System delivers more
arc-on time, fewer weld defects or reworks and superior weld quality with less training.
• One touch welding — Set up a new weld process with a touch of a button. Increased
quality and productivity with more arc-on time by no need to manually switch
polarity or cables between processes and fewer errors caused by incorrect settings.
• True Multiprocess machine — Improved productivity and stable arc performance
from one multiprocess machine. Includes conventional Stick, TIG, FCAW and MIG
welding processes optimized for pipe welding operations. Advanced RMD® and
Pro-Pulse technologies reduce number of required weld passes, reduce rejects
and allow stainless steel applications to eliminate the backing gas.
• Single system design — One machine designed to perform all of your pipe
welding needs — no additional capital investment purchases for multiple
machines. One machine footprint also maximizes weld cell space.

Maxstar® 200 STR

The Maxstar 200 STR gives you an edge when rain, snow or coastal environments
make welding challenging. This inverter-based DC power source is rated to operate
at top performance in difficult field environments for shipyard pipefitting and welding.
Weldcraft TIG torches are available in a wide variety of sizes for TIG welding in
confined areas and joint configurations.
• Easy to use — Incorporates a simplified operator interface with only the
necessary controls.
• Easy installation with Auto-Line™ — Allows for any input voltage hookup (115 –
460 V) with no manual linking. Operators can move to the next work location and
get powered up quickly — even when input power is dirty or unreliable.

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 Sheet Metal
Thin Materials and Confined Workspaces
Demand Innovative Welding Solutions
Give your sheet metal operators the ability to weld everything from vents and cabinetry to
showers and lavatories with Miller® TIG welding solutions. Working with thin materials like
aluminum, stainless, copper and nickel can be a challenge for your operators. Our AC/DC
TIG solutions allow operators to gain the control and flexibility to overcome these obstacles,
producing smooth, high-quality welds.

Dynasty® 350
The compact yet powerful Dynasty 350 welder allows for greater portability in shipyard
operations. Superior arc control and faster travel speeds deliver greater productivity and
superior weld quality while providing maximum energy efficiency compared to traditional
welding machines.
• Advanced AC TIG controls produce defect-free welds, improve cleaning action and
reduce etching.
• Small, compact size — Provides convenience and flexibility while conserving energy.
• Ensures proper penetration — Easily joins thick materials to thin materials for proper
penetration without blowing through the thin section.
• Spatter-free solution — Reduces heat input and eliminates over-welding to ensure
proper fit-up and alignment assemblies.

MaxalTIG® Filler Metal

A premium filler metal solution, MaxalTIG products include options for 5183, 5356, 5554 and 5556
alloys. These high-quality TIG filler metals ensure consistency no matter the application.
• Stretch-wrapped in bundles to eliminate moisture and fretting corrosion.
• Smooth beads — Maxal® filler metals create smooth, x-ray-quality welds.
• Consistent performance ensures quality welds.
• Extremely clean — Able to exceed the AWS porosity standard.

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 Sheet Metal/Training Welding Solutions
Training
Maximize Training Space and
Enhance Learning Environments
Skilled shipyard welders are a valuable resource. By investing in weld fume extraction to
create a healthier training environment, you’ll have an edge in retaining current workers and in
attracting new operators. FILTAIR® Weld Fume Extractors also improve your shipyard operating
efficiency in many ways, resulting in:
• Greater productivity — A healthy environment, free of fumes, is more conducive to focused
training that operators will quickly recall and implement on the job.
• Cleaner training equipment — Effective weld fume extraction keeps welding and personal
safety equipment cleaner. Trainees and instructors have less downtime cleaning welding
helmet lenses and training equipment lasts longer.
• Lower installation costs — FILTAIR weld fume extractors are fully assembled, fully
integrated and connect with clamp-together ducting for fast, easy installation.

FILTAIR Weld Fume Extraction

•L
 ess floor space — The ideal solution for shipyard training facilities, FILTAIR
requires up to 65 percent less floor space than traditional cartridge collectors.
•S
 uperior suction power — Ensures long-lasting airflow.
 ilTek™ XL filter line — Designed specifically for weld fume extraction,
•F
FilTek XL’s exclusive surface-loading media captures 85 – 95 percent of
submicronparticles commonly found in weld fumes.
• Minimize noise levels so students can hear the instructor without
noisy interruptions.
• Complete line of solutions designed to meet weld fume extraction needs
of all types of jobs and workspaces.

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 Safety
Improve Worker Safety and
Boost Shipyard Productivity
Arc Armor® Powered Air Purifying Respirator (PAPR) Units
• Personal protection — PAPR units provide personalized respiratory protection
and a clean-air breathing zone for individual welding operators.
• Increase operator comfort and improve productivity.
• Reduce fatigue — Lightweight design makes PAPR units easy to wear.

CoolBand™ and CoolBelt™ Heat Stress Cooling Systems

• Cooler under the hood — CoolBand headgear provides temperatures up to
8 degrees Fahrenheit cooler compared to the surrounding workplace air.
• Maximum airflow — CoolBelt belt-mounted unit delivers the maximum airflow
performance of up to 17 degrees Fahrenheit cooler. CoolBand
• Easily integrated — CoolBand and CoolBelt can be used with most Miller® helmets.
Both cooling systems provide air movement over the face and head, removing stagnant
air and decreasing lens fog. CoolBelt

WeldX™ Industrial Jackets and Cape Sleeves

• Repels hot particles — Miller-exclusive WeldX fabric repels sparks, spatter and
other molten metals.
• Lightweight base fabric won’t burn, melt, ignite or shrink.
• Outperforms in the toughest environments.

9400i Titanium Series™ Helmet

• Innovative aluminum heat shield protects the analog lens in high-amperage
applications.
• Auto-darkening lens flips up or down and integrates with a separate, clear grinding shield.
• Excellent skin coverage, and lightweight for extended wear.
• Reflects heat to keep the helmet and user cool.

Industrial Gloves
• Highly durable and superior comfort — Miller Arc Armor Gloves are the premium
choice in the industry, designed to endure the long-term, heavy use typical with
shipyard welding applications.
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Safety Welding Solutions

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Countless capabilities.
Trusted advice.
Integrated solutions.
Meet the challenges of welding quality and For all your shipbuilding welding
solution needs contact:
productivity in shipbuilding with the right partners —
Clay Byron
the ITW Welding companies. Miller, Hobart Brothers, Gulf Coast, South America
Clay.Byron@MillerWelds.com
Bernard and Weldcraft work together to create a
251-802-3265
comprehensive welding solution for your unique
Mike Novak
applications. ITW Welding will bring countless East/West Coast, Canada
Mike.Novak@MillerWelds.com
capabilities, trusted advice and integrated solutions 757-646-7981
to help you achieve your shipyard goals.

ITW Welding

MillerWelds.com HobartBrothers.com

# 258096 © 2012 Miller Electric Mfg. Co.