Mark/B-LOC: The most challenging applications are those in which components are subjected to continuous shock, vibration, or reversing loads, in these cases, keyless locking devices generate sufficient preload to ensure backlash-free connection.Jeff/KTR: Applications that include large reversing loads provide the greatest challenges.Vic/Rimtec: If the goal is accurate positioning, high-duty cycle, reversing loads are the most difficult, especially if they require high acceleration and deceleration.Jeff/Tollok: The most challenging applications almost always involve extremely high torques or heavy shock loads. Operational environment and other external influences can also be challenging.PitfallsWhat are the most common pitfalls and how can they be prevented?Jeff/Tollok: Selecting the wrong type of locking assembly is a big issue. Erroneous sizing calculations and improper installation and mounting are other pitfalls. My advice is to carefully review your application parameters with your locking assembly supplier.

For special applications, manufacturers offer metal-cored wires for GMAW. These are composite electrodes comprised of a metal sheath with a powder-metal core. They are often confused with flux-cored wires, which form a slag that completely covers the weld bead face; metal-cored wires produce very little slag. A major advantage of metal-cored wires is the ability to manufacture specialized alloy compositions not easily available or producible in solid wire fore1. Modifying the composition of the powder-alloy core allows the wire manufacturer to customize wire formulations to metallurgical, compositional, or physical properties per customer demand. Horizontal-fillet welds made with metal-cored GMAW can deposit weld metal at rates up to 20 percent higher than with solid wire. Alloying elements, such as silicon, in the powder-metal core improve sidewall wetting and reduce weld-bead convexity by reducing surface tension of the molten weld pool. For this reason, flat and horizontal welds deposited with metal-cored wires have better appearance than weld metal deposited with flux cored and solid wires. Compared to solid wires, metal-cored wires also result in higher current density, for increased penetration; a wider operating window with respect to welding-process variables: better sidewall melting; and less lack of fusion.

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