Welding Large Steel Fabrications

Welders at J & J Burning and Fabricating have been busy lately with several intense jobs for industries such as Mining, Aerospace and Plastics. In this photo, we are working on a Ramp Frame for the Mining Industry that requires 175 hours of welding.

Welding of a steel fabrication for the Mining Industry
To learn more about our capabilities, please go to www.jjburning.com.

The welding process, in various forms, has been around since ancient times. The following is a brief history of welding from the Middle Ages through the 19th Century found at www.weldinginfocenter.com:

History of Welding
Middle Ages
Welding can trace its historic development back to ancient times. The earliest examples come from the Bronze Age. Small gold circular boxes were made by pressure welding lap joints together. It is estimated that these boxes were made more than 2000 years ago. During the Iron Age the Egyptians and people in the eastern Mediterranean area learned to weld pieces of iron together. Many tools were found which were made approximately 1000 B.C.

During the Middle Ages, the art of blacksmithing was developed and many items of iron were produced which were welded by hammering. It was not until the 19th century that welding, as we know it today was invented.


Edmund Davy of England is credited with the discovery of acetylene in 1836. The production of an arc between two carbon electrodes using a battery is credited to Sir Humphry Davy in 1800. In the mid-nineteenth century, the electric generator was invented and arc lighting became popular. During the late 1800s, gas welding and cutting was developed. Arc welding with the carbon arc and metal arc was developed and resistance welding became a practical joining process.


Auguste De Meritens, working in the Cabot Laboratory in France, used the heat of an arc for joining lead plates for storage batteries in the year 1881. It was his pupil, a Russian, Nikolai N. Benardos, working in the French laboratory, who was granted a patent for welding. He, with a fellow Russian, Stanislaus Olszewski, secured a British patent in 1885 and an American patent in 1887. The patents show an early electrode holder. This was the beginning of carbon arc welding. Bernardos’ efforts were restricted to carbon arc welding, although he was able to weld iron as well as lead. Carbon arc welding became popular during the late 1890s and early 1900s.


In 1890, C.L. Coffin of Detroit was awarded the first U.S. patent for an arc welding process using a metal electrode. This was the first record of the metal melted from the electrode carried across the arc to deposit filler metal in the joint to make a weld. About the same time, N.G. Slavianoff, a Russian, presented the same idea of transferring metal across an arc, but to cast metal in a mold.

SOURCE: Hobart Institute of Welding Technology

Stainless Steel Machines

We are currently fabricating nine sets of bridges and bases that combine to become components of stainless steel Blow-Fill-Seal machines. These machines are used to produce small and large volume sterile liquid-filled containers used by the pharmaceutical, health care, and food industries. . This safe and sterile technology is considered superior by various regulatory agencies, including the United States Food and Drug Administration. A container is formed, filled and sealed in a continuous process, without human intervention, in a sterile enclosed area inside a machine. Examples of the containers that can be produced are: IV bottles, contact lens solution bottles, and squeezable beverage containers.

To fabricate these parts, J & J Burning uses prime, mill-certified 304 stainless steel plate in thicknesses ranging from 3/8” – 1 1/4”. Each set requires over 260 labor hours to manufacture. To ensure dimensional stability when building stainless steel fabrications, our welders employ pulse-puddle arc welding and all parts go through vibratory stress relief. These added processes eliminate warping and distortion and allow the parts to remain within a tight tolerance. For cosmetic enhancement, the parts are blasted with glass beads prior to machining to produce a smooth, bright finish.

These pictures show the bases and bridges in-process at J & J, along with the finished machine and a diagram of how it works.

stainless steel bases

stainless steel bases in-process

stainless steel bases and bridges in-process

stainless steel bases and bridges in-process

Stainless Steel Machine

complete machine and sample containers

how it works

how it works

Rotary Friction Welding

We are currently fabricating two mammoth steel weldments that will be integral parts of the largest Rotary Friction Welder ever built. This machine will have twice the inertia capacity of any other machine on the planet!
Rotary friction welding is a joining process which involves holding one part stationary while rotating the other. Under extreme pressure, the two parts are forced together, creating sufficient friction and heat to reach the forging temperature without melting. When the weld interface cools, the two parts are bonded at the molecular level and the welding process is complete.
This enormous machine will be used by the Aerospace Industry in the United States to build next generation jet engines that will burn fuel hotter than ever before. Hotter engines create higher thrust capacity, while at the same time reducing fuel consumption and overall costs.
The two weldments being manufactured at J & J are the Lower Base and the Head Stock. The Lower Base stands 42” tall x 134” wide x 368” long and weighs 126,000 pounds. The Head Stock will be 70” x 172” x 174” and weigh 165,000 pounds. Almost ten thousand pounds of welding wire will be used by our AWS D1.1 certified welders to join A36 steel plate up to 21” thick. Together, these parts will require approximately 1,600 labor hours to complete.
Welding the Lower BaseLower Base near completion
Head Stock Welded FabricationMoving the Head Stock