How the Bernard® IronPro™ Keeps Trains on Track at CSX Transportation
In Atlanta, Georgia, CSX Transportation keeps 1,848 trains running every day; a demanding job where every minute of downtime matters. Fast, reliable repairs are critical to keeping operations on track.
Before switching to the Bernard IronPro, CSX welders faced constant challenges. The intense heat of track repairs was tough on their old welding guns, which weren’t built to handle the job’s demands. Wire bird-nesting and other issues slowed them down, making it hard to keep up with repairs.
The IronPro changed that. Built for heavy-duty work like construction, shipbuilding, and equipment repair, it’s tough enough for the high-pressure environment of railroad track welding. With up to 450 amps of power, it delivers consistent, reliable welds even under the most extreme conditions.
Comfort is another reason welders love the IronPro. Its lightweight, slim neck design makes it easier to work in tight spaces on the tracks while reducing strain during long shifts. Less fatigue means the team can stay focused and get more done.
The gun’s versatility is a big plus too. Customizable neck lengths and other options make it easy to adapt to whatever challenges come up in on the tracks.
Since switching to the Bernard IronPro, CSX has cut downtime, sped up repairs, and kept their trains running on schedule. For the welders, it’s become a go-to tool they can depend on every day to get the job done right.
Learn more about the Bernard IronPro.
Improved Flux-Cored Welding for Heavy-Duty Field Use
Improved Flux-Cored Welding for Heavy-Duty Field Use
Understanding operator challenges is what drives innovation in the welding industry. For some, that challenge is outdoor welding, where using shielding gas is not optimal. In these extreme conditions, traditional MIG welding won’t necessarily work. Turning to a different process, such as self-shielded flux-cored welding (FCAW-S), allows for more effective welding in the field. When welding in harsh environments, operators require durable, rugged equipment that can withstand the elements and the nature of the work.
Operators utilizing self-shielded flux-cored welding demand a high level of flexibility and reliability in their equipment, which is why Bernard optimized the IronPro™ self-shielded FCAW gun to be extremely durable when welding in heavy-duty field operations.
Features that enhance flux-cored welding for heavy-duty applications
Operators need a gun that stays cooler in the hand and is lightweight, portable and reliable — handling the rigor of the toughest worksites while improving operator comfort. To improve usability and the overall user experience, IronPro introduces several enhancements to meet those needs and help overcome technical and operational challenges when out in the field.
Specifically, the IronPro 350 has a 350-amp rated output with a 60% duty cycle, making it ideal for operators working in construction, shipbuilding and heavy manufacturing. The design was further updated to include:
- Interchangeable neck options: The IronPro 350 features two rotatable neck options — one that’s 7 inches with a 60-degree bend radius and one that’s 12 inches with a 45-degree bend radius. These allow operators to ergonomically access even the most challenging, out-of-position welds. The neck can be rotated for a trigger-on-top approach, allowing for even more dexterity and customization at the joint.
- Sealed trigger: The trigger is designed to keep the area slag- and spatter-free, reducing maintenance downtime. Being non-metallic, it absorbs less heat, and it’s made with a sealed switch that helps keep out dust and dirt, leading to a longer lifespan.
- Lighter cable: The weight and bulk of higher amperage gun cables can lead to fatigue over extended periods of time. The cable for the 350 is lighter, making it more mobile and user-friendly for a welder on a day-to-day basis.
Incorporating all the updated design features mentioned above, IronPro 450 is also available for higher amperage applications, supporting up to 3/32″ wire size. IronPro 450 has a 450-amp-rated output with a 60% duty cycle.
Additional ways to improve field performance
To keep operators welding in tight positions longer, using AccuLock™ S consumables will increase contact tip life, resulting in fewer tip changes and increased overall performance with fewer points of failure. To further improve field performance, the cable liner incorporates Bernard® E-Z Feed™ technology, ensuring a reliable and smooth feed, minimizing chatter and poor arc characteristics. The superior feeding performance, paired with high-quality consumables, leads to more consistent welds, minimizing rework.
The tip insulator was redesigned to be more durable, withstanding more aggressive weld parameters to keep the electricity from short-circuiting between the tip and neck. Additionally, the insulator transitioned from being a slip-on to a thread-on, allowing it to stay in place better. These design improvements help minimize bridging from spatter and improve operator safety by ensuring the contact tip remains isolated to allow current to flow correctly through the wire to the weld puddle. Operators can choose between composite tip insulators, for increased joint access, or armored tip insulators, which are well-suited for higher amperage applications. These options allow operators to better customize their IronPro to suit the needs of their applications.
When welding heavy-duty applications in the field, operators need power, durability and consistency. The IronPro 350 offers improvements that exceed those demands. Welders can elevate their welding performance — and experience the productivity and quality benefits self-shielded flux-cored welding offers.
