THE LATEST PRECISION TECHNOLOGY

At MERRILL, we transform pieces of metal into peace of mind. Utilizing the latest precision metal technology, our certified welders perform some of the most complex welding fabrications in the industry – on components weighing up to 200,000 pounds. Our fabrications meet and exceed most industry standards including ASME, AWS, Military and DIN.

WELDING FABRICATIONS ON COMPONENTS UP TO

50,000 lbs.

We have more than 130 industrial power sources with capabilities including pulse, synergic pulse, cold metal transfer, surface tension, conventional constant current and constant voltage. Our robotic weld cells allow us to be most efficient on production volume projects. And every one of our multifunctional fabrication stations is outfitted with its own crane, enabling us to rotate and lift up to 30,000 pounds. Our work speaks for itself. In fact, our fixtures are so precise that they often bypass the need for machining.

We perform these processes on a wide variety of material, from mild steel and armor plates to aluminum alloys and titanium.

Our core welding processes include:

Submerged Arc Welding (SAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Flux Cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)

For our customers, peace of mind is possible when MERRILL expertise is behind every step of your manufacturing process. Click here to take a quick tour of our fabrication facility and see why we say "At MERRILL, anything is possible".

THE LATEST PRECISION TECHNOLOGY

At MERRILL, we transform pieces of metal into peace of mind. Utilizing the latest precision metal technology, our certified welders perform some of the most complex welding fabrications in the industry – on components weighing up to 200,000 pounds. Our fabrications meet and exceed most industry standards including ASME, AWS, Military and DIN.

WELDING FABRICATIONS ON COMPONENTS UP TO

50,000 lbs.

We have more than 130 industrial power sources with capabilities including pulse, synergic pulse, cold metal transfer, surface tension, conventional constant current and constant voltage. Our robotic weld cells allow us to be most efficient on production volume projects. And every one of our multifunctional fabrication stations is outfitted with its own crane, enabling us to rotate and lift up to 30,000 pounds. Our work speaks for itself. In fact, our fixtures are so precise that they often bypass the need for machining.

We perform these processes on a wide variety of material, from mild steel and armor plates to aluminum alloys and titanium.

Our core welding processes include:

Submerged Arc Welding (SAW)
Gas Metal Arc Welding (GMAW)
Gas Tungsten Arc Welding (GTAW)
Flux Cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)

For our customers, peace of mind is possible when MERRILL expertise is behind every step of your manufacturing process. Click here to take a quick tour of our fabrication facility and see why we say "At MERRILL, anything is possible".

FABRICATION CAPABILITIES

LARGE PARTS

Multiple overhead cranes with lifting capacity ranging from five tons to 100 tons.
Multiple ergonomic positioners that can handle three to 60 tons.
Multiple lifts that can elevate projects up to 100,000 pounds in one lift.

CLADDING

Our hot wire GTAW cladding services provide a highly versatile weld overlay for those applications that require corrosion-resistant properties. Our high deposition rate — 16 pounds per hour in flat position, three pounds per hour in horizontal — gives us the ability to complete projects with greater efficiency, without sacrificing quality.

CUTTING

Cutting, coping, notching, beveling and etching capabilities for any project in almost any material. Through CNC programming, we can cut through steel up to 12 inches thick. We can cut through 2,500 linear feet of 1/2 inch carbon steel in a single day. And three torch capabilities mean we can craft five-axis bevel headed cuts, straight cuts and precise high definition edging.

STRESS RELIEF

Having stress relief performed on-site at MERRILL helps shorten lead time and increase efficiencies while improving the stability of your components. Our thermal processes include heating parts up to 1300 degrees Fahrenheit for parts up to 30,000 pounds to achieve stability, reduce hardness and improve machinability; while our vibratory process can quickly stress relieve stainless steel and other alloys without altering the molecular makeup.

FABRICATION CAPABILITIES

LARGE PARTS

Multiple overhead cranes with lifting capacity ranging from five tons to 100 tons.
Multiple ergonomic positioners that can handle three to 60 tons.
Multiple lifts that can elevate projects up to 100,000 pounds in one lift.

CLADDING

Our hot wire GTAW cladding services provide a highly versatile weld overlay for those applications that require corrosion-resistant properties. Our high deposition rate — 16 pounds per hour in flat position, three pounds per hour in horizontal — gives us the ability to complete projects with greater efficiency, without sacrificing quality.

CUTTING

Cutting, coping, notching, beveling and etching capabilities for any project in almost any material. Through CNC programming, we can cut through steel up to 12 inches thick. We can cut through 2,500 linear feet of 1/2 inch carbon steel in a single day. And three torch capabilities mean we can craft five-axis bevel headed cuts, straight cuts and precise high definition edging.

STRESS RELIEF

Having stress relief performed on-site at MERRILL helps shorten lead time and increase efficiencies while improving the stability of your components. Our thermal processes include heating parts up to 1300 degrees Fahrenheit for parts up to 30,000 pounds to achieve stability, reduce hardness and improve machinability; while our vibratory process can quickly stress relieve stainless steel and other alloys without altering the molecular makeup.

ELECTRON BEAM WELDING

When your application requires deep penetration and low distortion performed to precise specifications, our 110”x110”x110” New Generation Electron Beam Welding System can handle the job.

With this system, we can accommodate small to large parts that specifically require EB welding. The CNC controlled unit can weld dissimilar metals that require deep penetration into the material to create high purity welds with minimal distortion. The end result is a clean precise weld, each and every time.

Machine Specifications

Internal chamber dimensions of 110”x110”x110”
1-1/4” thick vacuum chamber walls
30 kW computer controlled hard vacuum beam welder
Internally mounted low voltage 60 kV moveable gun (60/60 type with high resolution optics)
30 kW power supply rated for 500 mA at 60 kV
Constant voltage within +/- %1

Compatible Materials

Steel Alloys
Aluminum Alloys
Stainless Steels
Nickel-based Alloys
Titanium
Zirconium

Highlights

Welding of dissimilar metals
Deep penetration
Clean welds
High precision – CNC controlled
High purity welds
Low distortion – minimal heat used

FORMING

With one of the largest high tonnage press brakes in the state of Michigan, we can form large scale projects with up to 2000 tons of force. For smaller scale projects, our 250 ton press brake can bend metal up to ten feet in length.

STRAIGHTENING

With 1,000 tons of steel straightening power, we can straighten fabrications, bearings, bushings, steel and aluminum plating — from small, intricate components to multi-ton parts. Our multiple presses can form steel from 1/2 inch to ten inches thick.

MERRILL serves as the trusted fabrication partner for manufacturers in a wide variety of industries. Check out our latest high speed rail project here and see the MERRILL difference for yourself!

STRAIGHTENING

With 1,000 tons of steel straightening power, we can straighten fabrications, bearings, bushings, steel and aluminum plating — from small, intricate components to multi-ton parts. Our multiple presses can form steel from 1/2 inch to ten inches thick.

MERRILL serves as the trusted fabrication partner for manufacturers in a wide variety of industries. Check out our latest high speed rail project here and see the MERRILL difference for yourself!

THE SOLUTIONS YOU NEED

MERRILL makes anything possible. From concept to completion and beyond, our top-to-bottom capabilities mean that we can design, build, test and deliver nearly every operation imaginable.

Solutions