• The World’s Largest Web Site on MIG, Flux Cored, TIG and TIP TIG Weld Process Controls & Best Weld Practices

Welding Processes Made Simple.

Welcome to most authoritative global web site on MIG, Flux Cored, TIG and TIP TIG weld process controls and best weld practices. This site simplifies  the weld data and the weld process controls, and best weld practice requirement. The site also provides the self teaching and training resources that are necessary for a weld department to consistently attain the highest possible, manual and robot, weld quality, always of course at the lowest possible weld costs. The site was established around 1998 by Ed Craig. Please refresh the page if you are a frequent visitor. You can contact E Craig at  ecraig@weldreality.com.

MIG, Flux Cored, TIG & TIP TIG, Weld Process Controls & Best Weld Practices

Weld Process Controls – Best Weld Practices.

The 2017 missing weld link in most global weld shops, has for more than five decades been a front office and weld shop floor “Lack of Weld Process Controls &  Best Weld Practice Expertise”.

In the high tech industries, such as the Aerospace, Defense, Power, Medical and the Oil Industry, you would expect the highest weld engineering and weld manufacturing standards. You would also expect the high tech companies to use a modern day weld manufacturing approach that daily would encompass weld process controls and  best weld practices. The reality is that too often with the important global industries, you will find at the majority of their weld manufacturing facilities,

  • the use of outdated weld specifications and procedures,
  • inappropriate and poor weld procedures,
  • a lack  of uniform best weld practices,
  • a lack of shop floor and front office manual and robot weld process control expertise,
  • experienced weld personnel playing around with their weld controls,
  • the person with the most weld expertise is the local weld salesman who has rarely worked in a welding shop,
  • lack of management & engineering weld process ownership.

Spy plane relies on critical welds

High tech industries in 2017,  and their too often
1960’s approach to the welds they produce.

Few of the global automotive plants or ship building yards are  aware, that without front office management and engineering weld process ownership, it’s simply not possible to consistently attain optimum weld quality at the lowest weld costs.  

Apart from the weld quality – productivity and costs ramifications that is generated by a lack of weld process expertise, the companies that today provide welded parts need to constantly look over their shoulder at the ever encroaching global lower cost labor competition.

MIG and Flux Cored account for the
majority of welds produced daily

Both the manual MIG and Gas Shielded Flux Cored weld processes account for over 85% of welds produced daily with TIG and SMAW accounting for most of the other welds. Irrespective of a manual welders skills, these four arc welding processes have inherent process & consumable issues that will negatively effect the weld quality and production attained.

Robot MIG problems and the Automotive Industry.

For most robot arc welds, the MIG weld process is utilized. The largest user of robot arc weld is the automotive and truck industry. In these global weld manufacturing facilities too often poor robot MIG quality and productivity is attained daily. And the robot issues and resolutions are discussed extensively in this  web site.                  

The use of the outdated TIG process.

When high quality all position welds and welds on difficult alloys are required, for approx. six decades the manufacturing industry has utilized the GTAW, commonly called TIG. The TIG process is the arc process that has required the highest welder skills and also generates the highest weld labor costs. For more than a decade the regular manual TIG and the automated HOT wire TIG processes have been outdated arc processes.  

The TiP TiG arc welding process

Still in use in 2017, outdated Hot Wire TIG
used to clad weld sub sea valve,

In 2017 as its been for six decades, those companies that have high manual arc weld quality expectations, will turn to the traditional TIG  process. The weld reality is in 2017, that more than a decade ago, the traditional TIG  process and the automated HOT Wire process evolved into a process called TIP TIG. However due to the common global front office management and engineering weld process ignorance and apathy, and also the often entrenched shop floor reluctance to change, the majority of  weld shops are today still utilizing the out-dated TIG weld technology along with their out dated weld specifications and procedures.

Both car and truck plants employ more engineers than most other manufacturing facilities, yet the last place you would look for manual & robot arc weld process control expertise, is in their front office.

Poor manual MIG welds on Auto Frames.Manual welding in automotive plantsBillions lost each year from lack
of arc weld process expertise.

Each year in North America over two billion dollars is lost in unnecessary  MIG – Flux Cored weld rejects, weld rework and poor weld productivity.  Also millions of dollars are lost daily in those weld shops that use the outdated TIG process with it’s unnecessary high skills and labor costs.

Arc weld manual, automated and robot weld process – best practice expertise is easy to learn,  and it is attained at this web  site.

For two decades global arc weld robot sales have increased dramatically each year,  and in 2017 Robot sales are at an all time high while Weld Process Controls & Best Weld Practice expertise is at an all time low.

Robot welders
When front office weld decision makers lack weld process control expertise, and their  never ending weld shop issues are like an old tooth ache, it’s not uncommon for the key weld decision makers to turn to who they think is the local weld expert, their weld distributor sales reps. This is typically an individual who in 95 out of 100 cases has never run a weld shop.


In 2017, Tesla will be glad to be aware that “playing
around”  with robot arc & resistance weld
controls, 
has for decades been an industry norm.

Robot welds depend on accurate data

Few of the million plus global robots utilized in 2017 will achieve their arc or resistance weld quality and productivity potential. The irony with arc welding is the robot and manual arc process control – best practice  expertise is easy to learn and only costs a few dollars.  One might ask, if weld process control expertise is  easy to learn and costs little, why is it not being implemented in all global weld facilities? The reason is for decades, most managers, engineers and supervisors simply don’t understand they lack this important expertise, (not taught in most colleges or universities and trade schools), and therefore they are not aware that it’s an  expertise that they and their shop floor employees need.

Like most automotive plants the Tesla mfg. management simply lacked the process expertise. And they also lacked awareness that the expertise existed and was essential.

Tesla calls: In the spring of 2017, I got a call from some Science or Engineering manger at Tesla California. This high level  manager had received my resume and he wanted to know how I could assist their new Model Three Production Plant with its MIG and resistance robot welds. The TESLA  plant  was getting ready to dramatically ramp up production on the Model 3 from a few hundred per-month to over 20,000 units a month in 2018.

Tesla & lack of management expertise. As our discussion went on, I could tell this TESLA manger had no expertise on the subject he was discussing with me. He was asking questions that you would ask some weld novice at a community college. I asked him had he read my 8 page resume. My resume spells out why for decades I have been an arc manual and robot weld process control – best practice expert. My resume also spells out that I had developed a unique Seven Step training approach to robot weld process controls and best weld practices and that I had  used these programs for weld process improvements in over 1000 plants in 13 countries.

So how would I resolve the Tesla weld issues: So what could I do for the Tesla managers and engineers who daily take on the role of firemen as they try to quench the never ending production flames influenced by their weld processes?  I could have quickly trained those individuals responsible for weld decisions with the process expertise necessary so they could all walk the one path necessary to attain optimum, consistent arc & resistance robot weld quality & productivity.

With the inexperienced Tesla engineer I again emphasized the information as provided in my resume that since my days of a[part from being a Robot Weld Manager with the world’s leading robot mfg, that in the last four decades I have provided manual, automation and robot robot weld optimization and training to the majority of the world’s largest Fortune 500 companies and the majority of the major auto manufactures  and their tier one suppliers.

Resolving major robot weld quality – productivity issues.

Above, just a few of the products that Ed improved
robot weld quality and productivity on.


Tesla and the influence of their unqualified management:

I then explained to this highly placed  manager, (who from my perspective was definitely  in the wrong job), that his upcoming extensive increase in robot weld production would without question lead to arc and resistance robot weld quality – productivity issues that were way beyond the auto industry norms. I spoke for another 30 minutes providing info on my robot past achievements and my unique process control expertise.  The manager then replied, “well that’s all very impressive, but I have to ask you this question, “What is MIG”.  After coming out of a state of shock.  I replied that “I don’t normally waste my time talking to an idiot”  and hung up.  Six to seven months later, read on where Tesla is today in the fall of 2017 with it’s weld processes.

A report from the Automotive News on the story that Tesla could be dealing with some major assembly-line weld problems that are slowing down production of it’s Model 3 sedan. TESLA produced only 260 Model 3s in the third quarter of 2017; while it expected to build 1,500 in September alone and ramp up to 20,000 a month by the end of the year. According to Automotive News’ Katie Burke, “based on details in a Wall Street Journal report and in a video of the production line posted on Twitter by Tesla CEO Elon Musk, experts say the electric vehicle maker appears to be struggling with welding the mostly steel vehicles.”

As Fruehauf and Volvo are aware with their costly trucks, product durability may be more important than driverless trucks with two laptops in a cab and a generous battery mileage range. In contrast to cars, when these companies  build trucks their welded components may be part of a 1 million mile truck warranty, and yet the arc and resistance robot welds required on these trucks are  still after decades of their experience,  causing many issues for them and for the rest of the  worlds major truck builders. To be able to minimize the robot arc and resistance weld issues,  takes a level of process  expertise that quite frankly the senior managers in the auto – truck  industry have never had,  and it’s sad to say that in 2017 they are still in the dark.

Tesla’s next product wll definitely have
technology versus durability issues.

2017: Note from me to Tesla.   Elon, I love your unlimited
vision on life, however as you are no doubt aware it’s easy to put  visions and prototypes on a pedestal and get share holders exited, and it’s another thing to successfully build products within the production, quality and cost projections. The auto – truck products that you are involved with will be influenced by numerous variables from die wear on stamped parts to processes expertise.  Please don’t get to frustrated  as lets face it, if the auto giants had the necessary talent to be successful in their production goals, they would not require their tier one – two suppliers. And if their tier suppliers were highly competent in managing their weld processes, they would not daily have production issues and have pallets full of rejects and rework.

A VISIONARY IN BOTH DESIGN AND THE  PRODUCTION METHODS REQUIRED TO BUILD THE PRODUCTS, LIKE STEVE JOBS,  NOW THAT’S A PERSON WHO IMPACTS THE WORLD.

Note: Aerospace and defense are other global industries that in 2017, and  as its been for decades you will find the Fortune 500 companies that produce welded components using out-dated weld specifications and procedures, outdated or ineffective weld technology and  front office / shop floor weld decision makers who lack weld process control – best weld practice expertise

Tesla and Spacex.  Some may see the  irony in an organization not being able to provide the process controls necessary for optimum robot welds on the present day low volume  car production, yet at the same time being responsible to produce consistent optimum weld quality on space craft.

Major weld issues  from Oil Tankers to Aircraft Carriers;
An oil tanker may have poor quality welds
Thanks to managers who lack process ownership
capability, the world’s worst welds will
often be found in ship yards.

An aircraft carrier may have poor quality welds

It’s the norm to find a lack of experienced weld process control managers, supervisors and engineers in ship building yards, and the costs of weld defects per-ship will typically go over budget by many millions of dollars.

From the Ship Yards to the global Auto / Truck plants, from the world’ largest Aerospace and Defense contractors, to the global Oil companies, Medical equipment  and  Construction equipment makers, most weld quality, weld productivity, weld  liability and weld cost issues are usually derived from the front office management and the weld shop floor supervision’s lack of weld process controls and best weld practice expertise.

The lack of manual & robot MIG weld process control – best weld practice expertise has for more than five decades been especially evident in the global Auto – Truck industry. Today in 2017, this is an industry in which most of its arc welds are made by MIG welding robots and attaining daily, consistent, optimized Robot weld quality and production is as rare as finding an honest politician.

MIG – TIG – Flux Cored are the world’s three prime weld processes. After assisting over a 1000 plants in 13 countries with their weld issues, I can say from my perspective, that few of the responsible managers or engineers that I met were aware of their real weld costs, or aware of their real world daily weld quality, production potential. So I did something about this lack of expertise, Over the last three decades I created the weld process resources they need, and then I made the costs of those resource so low (< $300) that even the most tight fisted manager who likely does not know what weld process controls / best weld practices are, will with only a small grumble pay this exorbitant weld costs.

Can you think of another high tech industry that for decades has relied extensively on inexperienced sales reps for process technical advice?

Inexperienced sales reps may not give accurate welding technical adviceProviding Weld Process Control expertise can be highly cost effective especially when robots are utilized, and no other industry uses more arc welding robots than the global Auto – Truck industry. In my position one time as the North American ABB Robot Weld Manager, I found the following robot MIG welding facts;

Management influenced automotive robot weld issues.

  • Average global “real world” robot down time is  40 to 70 minutes per-shift. This data is often unknown by many managers as it’s not correctly reported or documented. With weld process control expertise, it should not be more than 15 minutes per/shift.
  • Average global robot weld rework per-shift,  25 to 75 %. Typical management solution, hire extra manual welders to keep up with the robot weld issues.  With weld process control expertise, it should not be more than 5%.
  • Average robot weld rejects 5 – 20% per-shift. Management solution, attain a contract with a local scrap dealer and fudge the daily reports, With weld process control expertise it should not be more than 2%).
  • Average robot weld production efficiency per-shift. 40 – 60% of the real weld potential. Cannot be maximized without robot weld process controls – best weld practices.

You would think that it’ would be a logical engineering requirement, that front office personnel who have an influence on the robot MIG  – TIG or Flux Cored weld decisions, would be aware of the importance of the  weld process controls & best weld practice expertise necessary for robot weld optimization. The irony is it only takes a few dollars and a few hours with my  self teaching / training materials to learn that required WELD  PROCESS CONTROLS & BEST WELD PRACTICE expertise

With the MIG  the process control expertise is required to understand and optimize the four distinct MIG weld transfer modes. Understanding the MIG weld modes, the weld consumables and the weld / wire parameter ranges, and then matching the best possible MIG data to the specific weld application, are logical weld requirements for both the weld shop personnel and front office weld decision makers. If this sounds complex, please note that with my training materials,  you only have to learn three simple MIG or flux cored weld settings and a few Best Weld Practices for weld quality – productivity optimization on any manual or robot MIG weld application.

If managers and supervision would do their job, the welds quality improvements and cost savings could be dramatic.

The extensive robot or manual weld cost savings that I would generate at plants, would typically take no more than two or three days to implement. In that period I would also establish the required weld  process control and establish the best practices. Then I would provide one of my  training Programs. What I thought was ironic in most of the plants that I provided the weld quality / productivity improvements, was the responsible weld supervisors, managers, engineers and other front office weld decision makers would typically show little interest in the process control – best practice training. However being a stubborn thick skinned bugger, I would insist that I would not provide the weld process improvements and the training unless they at least took an interest and attended the short process improvement training programs.

Weld process controls cannot be effective, unless all those involved with the plants daily weld decisions decide to walk the same path to weld process optimization.

Over the last four decades in numerous global plants, I readily generated over 250 million dollars in arc weld quality – productivity improvements, and those are savings that usually continue for years. With robot arc welds. I was requested by companies such as GM, TOWER, DANA, MAGNA, TOYOTA, VW, HONDA, CHRYSLER, FORD, HARLEY, MERCEDES & numerous others to assist them with their robot weld issues. I have also managed ship yards and worked on nuclear plant weld repair projects. I have advised on the Space Station and Mars Landing Craft welds. It did not matter what the code utilized or the application was, the first thing that i would focus on, well you know what.

Weld Psychology 101: Try this. Have a chat with your wife or girlfriend about welding and look closely at their eyes. Then chat with the front office mfg. management about the never ending weld department issues,  and in the majority of instances you will note the same glazed look:

Administration and management need to take responsibility for weld quality, too.

Front office personnel and supervisors, when discussing welds for gods sake please try and take a position of ownership and show a genuine interest on  the subject. Also please resist the urge to bring in a salesman for  their opinion on the subject. Imagine the benefits you could bring to your organization and your pay check if you actually learn about MIG – Flux Core – TIG – Tip Tig weld process controls and best weld practices.   

MIG – TIG – Flux Cored and  TIP TIG Weld Process Controls & Best Weld Practices are essential for weld decision makers who want the best weld results with the lowest weld costs  from either their manual welders or from their robot  cells.

The photo shows the robot MIG parameters are not optimum. It would take 5 minutes to fix. The reason it was not addressed by the robot technicians is because they lack process control expertise, and they will continue to lack that expertise till someone in the front office wakes up.

The robot MIG parameters are not optimum

The following is a pathetic engineering statement for an important global industry.  “Too often a weld SALES REP” will have more process ownership and  influence on a companies weld shop decisions, than the primary weld decision makers that run the weld shop.


How often does your weld shop have to ask a salesman?

Salesmen do not have the answers for welding problems


A question for weld decision makers. 
Are the weld personnel in these facilities qualified to make optimum manual or robot weld equipment, consumables, process controls and best weld practice decisions, or are they seeking  the expertise of other inexperienced personnel?  For decades this has been a global sad reality.  Its Monday morning,  the local weld salesman who in most instances has  never have supervised or managed a weld shop, marches through the weld shop door with a box of donuts  or a pizza. After a while of listening to the weld shop issues, he then presents his companies latest costly pulsed bells and whistles power source and wants to let you know about the latest magic three part MIG gas mix, that’s sure to be a  solution to what in reality is,  lack of weld process control expertise.

YOU MAY HAVE NEVER HEARD THIS IN YOUR WELD SHOP. “I have been a skilled welder for more than 30 years, and if I don’t know a weld setting I will just play around with the weld controls. Anyway why should we learn something new and change the way we do things? after all this is the way we have always done It”.


In 2017, this guy would be at home in many
global pipe and vessel weld shops.

Skilled welders need to stay current and not rely on years of experience alone.

The meaning of weld quality in different industries,
is 
often different strokes for different folks:

In contrast to the industries which primarily use the MIG and Flux Cored process, there are the industries or weld shops that will daily strive to deliver the highest possible weld quality with every weld they produce. These weld shops will be familiar with the TIG (GTAW) and SMAW (STICK) process. These two older weld processes have something in common in that they both use a Constant Current (CC) power source that has one single prime control. Amps Up – Amps Down.


If you wanted to write a book on management – engineering weld process control apathy and ignorance, after visiting the Auto – Truck plants and Ship Yards, then make a tour of the Oil – Gas industry facilities.


Other industries stuck in the 1960’s.

Many industries are using outdated processes.

In the Power, Aerospace, Defense, Oil, Gas and Medical Equip. industries, you will typically find much higher code weld quality requirements than that found in the plants that produce trucks or tractors. While these industries demand higher quality you will find in the front office a lack of weld process control and best practice expertise.

The reality in 2017 is that in most of the high tech companies, you will find that from the design to the engineering department, or from the QA office to the  mfg. management office, that weld process control – best practice ignorance is the norm,  and these are subjects that will rarely be discussed.


Aerospace a great industry, however too often, outdated weld specs. and inadequate weld procedures utilized.

Ed worked on the Space Station & Mars Space Ship welds

Ed worked on the Space Station & Mars Space Ship welds. On reviewing the weld specs and procedures most commonly used, he was amazed to learn that most of the arc welds were made with weld specifications and procedures that have changed little since first introduced in the 1960’s to 1980s.

Weld technology has been be slow to evolve, but by god no
matter what 2017 aerospace engineers think, it has
evolved, otherwise I have been asleep for the last 50 years. 

2017: After 50 plus years optimizing arc welds , you could assume that I have not been asleep on the couch with the TV remote control in my hand. I learn and evolve every day.  What I know in 2017 about weld process control & best weld practice requirements that are necessary for an organization to  consistently attain, optimum TIG or MIG  weld quality, and what I knew in the 1960’s to 1980’s, would be like discussing  the differences between chalk and cheese.

When that NASA, or SpaceX built ship eventually heads out on it’s long dangerous journey to MARS, it will have been mostly welded with approved arc weld specs and procedures that were influenced or even generated between 1960 and the 1990’s. Yes there will have been procedure revisions, however  those revisions, usually grammar will be rubber stamped so someone in the office can put their name on them. The spec revisions  will have rarely impact the procedures and still leave them so that the weld processes utilized. do not attain the weld quality potential.  The irony is most of the arc weld quality control in the Aerospace and Defense industries will in 2017 be not left to engineers,  but left  to self taught Fred, Bill and Joe in their weld booths,  and you all know where that liability door opener has the potential to end up.


Why change – Why Change – Why Change?

People resist change
How often is Aerospace – Defense weld quality left
up to Fred or Joe a welder in the weld shop?

Perhaps someone in the Aerospace / Defense company front office that’s still  awake in the  21st Century, should inform the relevant engineering managers at NASA. SpaceX, and their suppliers such Boeing, Northrop, Lockheed, Airbus, Raytheon, GE and many others, that reference the  “TIG – MIG weld processes they use”, it’s time their engineers came out of that Black Hole, (their front office) and review and update their weld specs. and procedures. The updates would reflect the process optimization expertise and best weld practice changes that have been learnt since the processes were introduced.

Perhaps the weld responsible  Aerospace – Defense engineers  could in  2017,  “Boldly Go Where Few of the Engineer Have Gone Before”  and learn about the weld Process Controls – Best Weld Practice requirements under discussion. In doing this task, the weld decision maker will with  a few hours with my my training resources,  have the requirements necessary to actually take Weld Process Ownership, This step allows the engineer or any weld decision maker to take “One Small Step for the weld decision maker,  and One Giant Step for their company”. After all, who wants to  be that company and engineer that’s held responsible when a weld fails on a space flight that’s half way to Mars?


So again, great robots, good application,
lousy weld data, poor weld management.
Great robots, good application, but lousy MIG data, means poor welds

If you know MIG weld process controls,  and I tell you the wire size utilized, you should be able to look at this photo and be able to tell me the wire feed, volts and robot weld travel rate, and then tell me whats wrong with the weld  and how it can be fixed.

When you find that lack of weld process control for manual or robot welds is lacking with front office personnel, you will always find the same lack of expertise on the weld shop floor. When management, engineers, supervisors and technicians lack an expertise required for the processes they daily utilize, this can create the following;

  • weld facilities that rarely attain their optimum weld quality – productivity potential,
  • weld facilities that will frequently rely on vendors and inexperienced sales reps for assistance with their extensive weld issues,
  • weld facilities that constantly search for  a new crutch for their weld issues. The crutch may be the purchase of a new sophisticated costly power source that’s often loaded with useless electronic bells and whistles. Or the purchase of another useless three – four part gas mix,
  • weld facilities who’s who have to add to their manpower or overtime costs as the managers and supervisors are daily in the FIREMAN mode, forever fighting but rarely resolving weld issues,
  • weld facilities that never seem to produce a weld team that can consistently attain process optimization or quickly resolve the weld shop issues,
  • weld facilities in which the front office weld decision makers do not fully understand their real weld costs and therefor lack the ability for their companies to be cost effective,
  • weld facilities that will fear process change,s and therefore will not embrace the effective process evolution and expertise that are necessary to attain the highest weld quality at the lowest weld costs.
  • too many weld shops will build up their QA dept budgets, and place their  mfg. focus on FINDING RATHER THAN PREVENTING WELD DEFECTS,  (not cost effective). Its logical if you employ weld inspection personnel that you should provide them with this type of training.

So the MIG process accounts for approx. 80% of the global arc welds produced daily. In 2017, I believe that it’s about time that primary weld decision makers evaluate their positions on Weld Process Ownership Responsibility and Accountability. Companies would benefit greatly if they recognize that to compete in the global weld market place and  consistently attain optimum weld quality / productivity at the lowest daily weld costs, all weld decision makers and shop floor weld personnel should be provided with the Weld Process Controls and Best Weld Practice Expertise, For the price of a good dinner, it’s  available at this site.

For most weld shop managers it’s this simple. With arc weld processes, you own, you optimize, you control, you train, you learn, you evolve, you work as a team and every day you work hard, or you loose the bloody work and the jobs.

Outdated processes can be improved if we accept the need for change
Thanks to global management and supervision weld process ignorance, it took approx. three decades for many N. American companies to accept the fact that on their weld applications that gas shielded, flux cored was a far superior process than bloody STICK welding.

Experienced MIG weld decision makers are aware that with  process expertise, MIG weld optimization can be derived with low cost MIG equipment, the correct consumables and low cost two part gas mixes. Those that make MIG or Flux Cored weld decisions, or who simply have an interest in weld process controls and best weld practice expertise, may want to review the following weld process questions. And then consider the weld quality, production, costs and liability relevance of process expertise required to answer the questions.

Welding

E Craig’s MIG Weld Process Controls Test.

E Craig’s Flux Cored Process Controls Test.

This site was established around 1998. If you take the time you will find many logical weld solutions and also the WELD PROCESS – BEST PRACTICE PROGRAMS that can enable front office and weld shop weld decision makers to take complete WELD OWNERSHIP.  The bottom line is this site provides the weld industry with the resources required to reduce their weld liability concerns and enable weld personnel to stop PLAYING AROUND with weld equipment controls. Click here for your weld process optimization materials

When I visited Defense contractors to assist them with their weld issues, I quickly learnt not to have high expectations  that I would find MIG, TIG or Flux Cored weld process control and best weld practice expertise in the engineering dept or the front office. Of course there were exceptions, but they would be as rare as an honest politician.

Its worth repeating that frequently the places that typically have the highest ratio of engineers to welders will often be the places where you will often find the highest weld repair costs. For those few managers that show an interest in welds, there should be a message that comes from this statement.

Aircraft carrier - the places that typically have the highest ratio of engineers to welders will often be the places where you will often find the highest weld repair costs

From Textron, GE, Boeing and Northrop, few of the fortune 500 companies employ managers or supervisors that understand the necessary process control – best practice requirements to minimize costly weld rework and also to attain the highest possible weld productivity.  

In 2017, a global Fortune 500 company could be building Satellites or a Space Ship destined for for some far planet in outer space, or perhaps the company is constructing the latest Nuclear Submarine, Aircraft Carrier or Jet engine parts. The weld reality is that it would take me less than an hour at most of their facilities to prove that many of the critical daily welds produce are rarely at the weld quality / productivity levels that they could readily  attain.

Management, Engineering, Supervision, Ownership & Responsibility: When something that impacts the weld quality and production is missing in a weld or mfg. department, those in the front office have the “Engineering Responsibility” to both recognize and provide it, especially when that thing is easy to lean and costs little. I hope I have your attention. If you are upset about my message, perhaps your time will be better spent with the donut sales rep. If however you have weld questions, you already know I love to chat about this subject, you can call me at 828 337 2695. Or like me if you don’t have a life outside the subject of welding, you can go through some of the million plus words that I have written on the process controls – best practices available at this site.

Ready to take your company down the path to weld process optimization?  Please review my self teaching / training Weld Process Controls – Best Weld Practice Resources.

The application did not matter.

Ed repairing Textron (Florida mfg.) Stingray Tanks in Thailand
From the MIG / flux cored major weld repairs required on the Textron (Florida mfg.) Stingray Tanks that were over in Thailand, (above photo), to optimizing the robot Frame welds on the worlds largest selling Ford F-150 trucks, or establishing the robot welds on Harley and Indian bikes, and providing weld process control expertise to improve welds on UK Submarines, USA Spaceships or Air Craft Carriers, for me this this job has always been a joy. The application was not that relevant its was always about the process requirements and the weld practices necessary to control the weld pool. For approx. 50 years, I provided weld process optimization for more than a 1000 companies in 13 countries, and the programs available at this site are the result. These training – self-teaching Resources, are now in use by more than 3000 companies in 27 countries.

Now that Ed’s an old fart  he is still going uphill in a industry that
for decades seems determined to go  down hill, so where is Ed in 2017?

Mars probe - In 2017 Ed was assisting United Technologies / Boeing / NASA with complex weld projects that are part of the Space Station and the ORION Space project.

In 2017 Ed, sorry now Em, was assisting United Technologies / Boeing / NASA with complex weld projects that are part of the Space Station and the ORION Space project. (ship to Mars). It was a great opportunity to work with people that still no little about weld process optimization, but when it comes to out of this world engineering, all I can say is WOW.

WHAT IS NOT NECESSARY IN MOST WELD SHOPS.

  • Is complex, costly Pulsed MIG equipment for common steels.
  • Three part MIG gas mixes or any mixes that contain oxygen or helium.
  • Metal cored weld wires.
  • Weld rework or rejects.
  • Managers or supervisors that take more than 5 minutes to work out the cost of a weld.2017: What many in the global weld industry are not aware, is the great price that paid daily in the global weld industry for it’s lack of MIG – Flux Cored – TIIG weld process control – best practice expertise. To add salt to this statement, you could have said the same thing in 2017.

Its time to get the bull out of the welding business

American flagUK flag

Getting management and supervision motivated about their weld ownership responsibility, plus getting the BS out of the weld departments has always been part of my objectives during my plant visits.

I have been asked to assist  large weld shops in the USA, Germany, Canada, UK, Australia, Sweden, Norway, Spain,  Brazil, Thailand and Japan. In the majority of the plants I visited, I found that the front office weld decision makers would often show little interest in the subject of TIG, MIG – Flux Cored weld Process Controls – Best weld Practice expertise.

For me the weld process apathy and lack of weld process control expertise that I found in numerous weld shops was quickly made evident when I  examined the welds and reviewed the process data, the equipment and the weld consumables use. Also I found that common denominators in all of the countries i visited was that weld practice in which weld shop personnel “Play Around” with their MIG – Flux Cored weld controls. Also it never ceased to amaze me that after  I resolved the companies weld issues,  I simply came to the conclusion that those were really responsible for the weld issues all resided  in the front office.  Please remember on the subject of weld process ownership that in our industry, we are dealing with weld processes that usually have one or two simple prime weld controls, and these are weld processes that have hardly changed in decades

WHATS TO COST OF 3 FEET OF A 1/4 MIG FILLET WELD? If you wanted more proof of the lack of weld process control best practice expertise at a weld shop. Try this. Grab a coffee and head into the shop’s front office.  Try to find someone in the office that  is aware of the real cost of a yard (meter) of the most common welds they are daily producing. You could further then stir up the pot and ask why are there so many different power sources are being used in the weld cells. Or why was the costly costly pulsed MIG equipment purchased,  and why are costly useless three part gas mixes being utilized  for MIG steel or stainless welds?

Companies can take steps to ease the transition from manual welding to robot MIG welds

If the  weld shop has robots, you could waste time and ask why are those responsible for the robots playing around with the robot weld  data. Why is so much robot down time is being generated daily, and why is the high costs associated with the robot weld rejects and rework. You could also then ask those responsible about why the time and labor is being wasted on cleaning weld spatter and why throughout the robot weld department their is weld process confusion.  And of course just as you are leaving for the day you could drop in the engineering or mfg. managers office, look them in the eye and and ask;

“Is it logical that in this tier one  front office, that the key robot weld decision makers will often have to rely on a welds salesman for weld process or application advice, especially when we know the sales rep has degree in English or was it History, and he has never run a welding shop”?.


The manager may ask the right question,

but will rarely be aware of the right solution.

The manager asks why are we still playing around with that weld data

One of my MIG - Flux Cored Weld Process work shops in Cleveland Ohio

Photo above: One of my MIG – Flux Cored Weld Process work shops in Cleveland Ohio. Sixty weld decision makers attended this workshop. They came from companies located in six countries including Brazil and Australia. The seminar participants came to learn the extensive weld quality -costs benefits attained  from MIG – Flux Cored – GTAW Weld Process Controls – Best Weld Practices.

Seminar participants

THE GLOBAL FAILURE OF MANY WELD
EDUCATORS AND WELD TRAINERS: 

There are very few global Community Colleges, Trade Schools. Universities and other trade training facilities that have ever provided MIG – Flux Cored Weld Process Controls – Best Weld Practice education.

It’s an ironic point that the students who take weld courses will take programs that last months and for weld engineers up to 4 years. yet when the graduates go for a job they will end up “playing around” with their MIG and flux cored weld controls

NOTE: It should typically take between 7 and 10 days to teach someone who has never MIG or Flux Cored welded, the weld process expertise, best weld practice and the welder skills that are necessary to pass  any code, all position welder  qualification test.  I have provided this training many times and my training resources will show you how.  My first time welder qualification PASS RATE has been > 95%.

The Universities and Community Colleges that provide weld programs typically  don’t have professors or educators who are experienced with manual – robot  MIG – Flux Cored Weld Process Controls – Best Weld Practices. What we have after decades of process control ignorance / apathy,  is a global industry in which the majority of weld decision makers will at sometime play around with the world’s two most widely utilized weld processes.  When the robots are then ordered into a play around environment.  it should be no surprise that the robot technicians will also play around with the robot weld settings.

TOO MANY GLOBAL MANAGERS SEARCH FOR A
CRUTCH THAT THEY BELIEVE COULD BE THE MAGIC RESOLUTION FOR THEIR  DAILY WELD SHOP ISSUES?

GLOBAL MANAGERS SEARCH FOR A CRUTCH THAT THEY BELIEVE COULD BE THE MAGIC RESOLUTION FOR THEIR  DAILY WELD SHOP ISSUES

  • 2017. The MIG and Gas Shielded Flux Cored processes have for decades accounted for approx. 80 to 85% of the world’s daily welds produced, and GTAW and TIP TIG are the weld  processes  of choice when optimum weld quality is required especially with alloy welds. With the world’s four most important weld processes, It’s common to find the following in global weld shops;
  • Experienced engineers, technicians and weld personnel that too frequently “Play Around” with two simple MIG or Flux Cored weld controls, yet these are two weld controls that have hardly changed in decades.
  • TIG welders using incorrect tungsten size & type. Not being aware of optimum weld amp settings & using incorrect weld techniques.
  • Weld shops that use the stick and TIG for code welds, and are not aware that for more than a decade the TIP TIG process has been available.

Note: It would take me only 15 minutes in any global weld shop to prove that on 99% of all steel and alloy steel weld applications,  that the majority of the costly weld equipment products purchased provide no real value to the weld shops. The electronic weld equipment has certainly  increased profits to both the weld equipment / consumable manufactures and distributors, and wait till you see the cost of the weld equip. repairs.

  • Too many front office weld decision makers think it’s the norm to spend their days running around trying to quench weld shop fires, or they simply will sit by their computers, unaware of the benefits of the Weld Process Controls and Best Weld Practices. Expertise that could quickly enable their organizations achieve considerable weld cost savings.
  • TIG welders who have been TIG welding steels and alum. for years, yet both they and the front office personnel don’t understand the benefits of  Balanced Waves, Hz and pulsed controls when its provided on their  equipment.
  •  Weld decision makers who do not know their real  Weld Costs, and instead focus on the weld consumable costs which typically account for 15 to 20% of their weld costs. If decision makers are not aware of the optimum weld process requirements and weld deposition rate potentials for their common manual and automated welds, then controlling weld costs will not be possible.

Note: In the hundreds of companies that I visited in 13 countries, I never talked to a single key front office weld decision maker who knew the real weld costs of the common daily welds they produced.

  • Its a sad comment that in North America 2017, for those weld shops that TIG weld,  yet the management, engineers  and supervision is  not aware of the TIP TIG process. This is a process  that I introduced to N. America and Australia over a decade ago. The GTAW reality is, by using  TIP TIG,  one welder can produce the work of three traditional TIG welders, and at  the same time dramatically improve the TIG weld  quality and the weld / part  metallurgical properties.

questionable robot MIG welded frame & axles in American cars and trucks

If you own an American car or truck, as you drive over
pot holes, please give give consideration to your
questionable robot MIG welded frame & axles.


HE IS SUPPOSED TO BE A MANAGER OR SUPERVISOR,

HIS JOB DESCRIPTION SHOULD BE  “WELD SHOP FIREMAN”.

weld and QA dept. managers and supervisors become firemen

When weld process control – best practice expertise is lacking, you will find that the weld and QA dept. managers and supervisors become firemen, always trying to quench the weld shop flames but never knowing how to put out the weld shop fires.

If they don’t know it exists in the front office,
why should it exist on the weld shop floor?

If the management does not know Weld Process Controls and Best Weld Practices exists for either MIG – FCAW – GTAW, they and their weld personnel will not be aware of the weld quality, productivity and costs benefits that could be attained. This is the common status for most global weld shops, and when you add robots into this manual weld shop environment you know that robot weld quality or productivity issues are bound to occur.

Now that would be a novelty,
PROCESS OWNERSHIP – RESPONSIBILITY?

Process ownership and responsibility need to be clear

Throughout the global weld industry you will often hear corporate and plant managers complain about having to compete with much lower labor costs from other locations or countries. The irony is that the majority of these executives will not be aware of the weld process control – best practice expertise that’s lacking within their organization.

IN 2014, 60 MILLION VEHICLES WERE RECALLED IN THE USA, A PRETTY STAGGERING FIGURE FOR A COUNTRY THAT PRIDES ITSELF ON IT’S ENGINEERING / MFG. EXPERTISE, A COUNTRY THAT PRODUCES ON AVERAGE 14 TO 17 MILLION VEHICLES PER-YEAR.

Most of the major auto / truck recall defects will typically be the result of a poor decision made by a designer, manager, engineer. It’s anticipated that the latest vehicle recall costs for the auto industry, and the resulting long term law suites that will likely result could be some where between 10 to 20 billion dollars. The extraordinary loss of potential profit for the USA auto industry should be difficult to grasp in a manufacturing industry that is seen to be top heavy with university educated managers and engineers, an industry that has also in the last few decades spent billions of dollars implementing a variety of Quality Control Programs and mfg. Standards.

Photo below: Ed providing a two day Robot MIG Best Practices – Process Control Training program for robot technicians at a USA Magna plant. Magna is one the world’s largest auto / truck part suppliers. More than a decade has passed, and in 2017 decade most  Magna mfg. managers, engineers and supervisors would  not be aware that their robot technicians lack robot weld process control – best practice expertise. Click Here.

Ed providing a two day Robot MIG Best Practices - Process Control Training program for robot technicians at a USA Magna plant

2017: A lack of in depth weld process control knowledge, yet super confident in their ability to work with that process, is today an attribute that’s common with many young robot weld technicians.

Its easy to train young people who were suckled on a  lap top to program a robots movements and  become a robot technician.  however the reality is that the  majority of of global robot arc weld technicians are simply not aware of the required robot MIG Weld Process Controls and Best Weld Practice expertise that should be daily applied in their robot cells.

WHEN TECHNICIANS LACK A REQUIRED MFG. EXPERTISE, THAT DEFICIENCY LIES WITH THE RESPONSIBLE MANAGERS.


How do you define robot process optimization?

Robot welding process optimization

MESSAGE TO COMPANIES THAT SUPPLY ROBOT WELDED PARTS.
The best thing that the engineering management at Magna did for their robot welds was to provide parts to be welded that actually met their design dimension tolerance requirements. This by the way was one of the first companies that  I had ever seen in the auto – truck industry that had the engineering stamping / metal forming ability to provide decent part fit for their robot welds.

When gauge parts to be welded do not have dimensional and fit issues, and the parts are  optimum robot MIG welds,  then those parts should have few weld issues. With good part FIT, it’s easy for under qualified robot technicians to attain respectable robot weld quality / productivity with the common process data used in the plants. However the weld reality for most plants, is in most instances the robot technicians that are daily making the robot weld changes are;

  • rarely attaining the best possible consistent weld quality, as viewed by weld macros. rejects and rework.
  • spending too much time on robot weld cell down time  issues,  problems  that should be instantly resolved,
  • spending too much time in weld meetings. If there is not a process expert at the table, then you know what BS to expect,
  • are simply not aware of the weld speed or true weld production potential for the welds and parts.

With the above situations,  it’s rare for the Mfg. plants to attain minimum robot down times and attaining the highest possible weld quality – productivity. So the reality is most (not all) global robot weld techs have like many others in the weld industry, have  become “Play Around”  technicians. And what is the response from the front office, these guys, (women have more sense) will simply add more manual welders to deal with the robot weld rework – reject issues. As for daily  attaining the required robot weld productivity,  when that plan goes out of the door, the managers solution will be either order more robots or simply increase the weld shop overtime.

Now that I have finished with the management – supervision – engineer criticism, If you are not to pissed off and wish to use my highly effective Seven Step Robot MIG Weld Process Control – Best Practice program to teach your self, or to train your employees Click Here.

WELD OWNERSHIP – ACCOUNTABILITY – RESPONSIBILITY?

Weld ownership and accountability

This manager would be a rare find.

MANAGEMENT & LACK OF WELD PROCESS OWNERSHIP.

In the auto – truck industry, and in other large industries that have “multi-plant” weld / mfg. facilities, you will frequently find both corporate and plant manufacturing managers that operate their business from their office computers and I-Phones. Unfortunately from a weld perspective, few of the responsible corporate and plant managers will comprehend the manual / robot weld process controls – best practice expertise that’s required for the responsible personnel in their plants. This is the way it’s been for the 50 years that I have been in this business.

The good news for management, engineers and supervisors is that the weld process expertise and best practices required will fit inside most  brains, especially those brains that have an interest on the subject. You may also be interested to note that for three decades,  I have driven myself to simplify these programs. The bottom line is,  if you can tell the time,  you can use my CLOCK method to learn the requirements for MIG and flux cored weld process controls.

THE CALIBER OF WELD MANAGEMENT IS OFTEN REVEALED IN THE PLANT’S JOB DESCRIPTIONS. The lack of process control – best practice expertise of managers, supervisors and engineers will often be evident by the common, lack of, or poor plant job descriptions for the employees that work with the arc welding processes.

With the robot welds, the typical global job descriptions too often indicate that the managers do not comprehend the Robot Weld Process Control and Best Practices expertise that is required by their plant engineers, robot technicians, supervisors and maintenance personnel. Also a reflection of management expertise is seen in the too common poor utilization of robots. It’s the norm in many auto – truck plants, for managers to order new robot weld cells, while from both a MIG & Resistance weld quality – productivity perspective, the robots in their plants have always been under utilized.

Great ABB robot MIG weld application below. However the fire works display reveals the too common poor robot robot MIG weld settings, evident by the lack of control of the arcs and the excess weld spatter.

ARC WELDING ROBOT

IT DEFEATS THE PURCHASE OF AN ARC WELDING ROBOT TO ALLOW SOMEONE TO OPERATE THAT ROBOT AND THAT PERSON LACKS WELD PROCESS CONTROL – BEST WELD PRACTICE EXPERTISE.

A few reasons for poor ROBOT MIG weld results;

  • The lack of management – engineer awareness of the real robot weld productivity potential for the welds and parts produced.
  • The lack of management – engineering knowledge about the importance of the weld process controls and best weld practices that are necessary to consistently attain optimum weld quality.
  • The unnecessary robot cell down time that occurs each shift. In many plants 30 to 60 minutes per-robot each shift is the norm.
  • The too common poor engineering – mfg. practices that deliver robot welded parts that are not in accordance with the part design tolerances.
  •  Few designers understand the weld processes they recommend to weld their parts, and the frequent poor design of robot welded parts is all the evidence you will need on that subject.
  • Poor fixture design that does not allow optimum gun positions are common and add to the robot issues.
  • The selection of equipment in the cell that contains useless bells and whistles, or the lack of incorrect weld equipment and consumables.
  • Poor robot cell maintenance and unqualified maintenance personnel making changes to so called qualified welds.
  • Robot cell purchase orders that lack the appropriate weld automation demands that can ensure the daily robot weld production / quality goals are met .

MIG – FLUX CORED – TIG OR TIP TIG, MANUAL – ROBOT WELD PROCESS
CONTROLS & BEST WELD PRACTICE TRAINING AT YOUR FACILITY.


The following are ways to get my Manual – Robot Weld Process Controls & Best Weld Practice Training and Self Teaching Programs.

[1] You can order one of my easy to learn programs & have your personnel provide the training.

[2] You can request that I provide a customized a manual or robot training and weld optimization program at your location. I can in a week turn around any company, optimize the applications and provide their organization wth the expertise and training they require. Your choice call a salesman, or call Em.. 828 337 2695.

[3] Also if you wish, you can use my expertise by making me a phone in member involved in your weld discussions or weld team meetings. Call Em.. 828 337 2695.One Popular Program or Seminar I provide for large companies.

” HOW TO MANAGE A WELD SHOP & ENSURE MAXIMUM DAILY MANUAL – ROBOT
WELD QUALITY AND PRODUCTION, ALWAYS AT THE LOWEST WELD COSTS”. 

MY CUSTOMIZED TRAINING PROGRAM FOR YOUR WELD SHOPS.:

The following customized MIG & flux cored, Weld Process Control & Best Weld Practicetraining program is suited for managers, engineers, supervisors, technicians, QA personnel and welder trainers.

In the competitive global weld – fab industry, increased profits will be achieved by those companies that employ weld decision makers that do not have to rely on weld sales advice, and have the Weld Process Controls and Best Weld Practice capability for weld process optimization in their organization.

PROCESS TRAINING & WELD COST REDUCTION OPPORTUNITIES FOR YOUR COMPANY:

Extensive weld cost savings will be found in any weld department in which manual weld personnel and robot technicians no longer have to play around with their MIG and flux cored weld controls.

Extensive weld cost savings are generated in weld departments when weld processes, weld consumables, weld transfer modes, weld deposition potential and weld costs are understood by the weld decision makers.

Extensive weld cost savings will be generated when the manual / robot weld quality is consistently optimized, weld rejects and rework are reduced, and the prevention of weld defects is understood.

Extensive MIG weld equipment and consumables cost reductions are enabled in weld departments in which the weld decision makers no longer rely on weld sales reps for weld advice. These cost benefits will be many;

[] The weld decision maker will have the reasons and proof that your company does not need to purchase costly pulsed MIG equipment that’s typically loaded with useless electronic bells and whistles.

[] The weld decision maker will no longer need to purchase three part gas mixes or a variety of different gas mixes.

[] The weld decision maker will not require the costly metal cored wires and will think twice about the flux cored wires purchased.

[] The weld decision maker will dramatically reduce weld fumes and weld grinding enabling a cleaner safer environment and also reduce the requirements for grinding wheels & discs.

A QUALIFIED MANAGER WOULD BE AWARE THAT IT DOES NOT NEED A WELD TEAM TO RESOLVE ANY MANUAL – ROBOTS WELD ISSUES, IT SIMPLY REQUIRES ONE QUALIFIED INDIVIDUAL WHO CAN THEN TRAIN THOSE THAT ARE INVOLVED WITH WELD DECISIONS.

My customized programs typically last one to two days and i will also instantly resolve any weld issues you have in the plants and provide optimum procedures. Any participants will in a few hours become manual or robot MIG – FCA weld process controls experts.

For more info. E Craig. 828 337 2695. E-Mail ecraig@weldreality.com.


THE VALUE OF MIG WELD PROCESS CONTROL – BEST PRACTICE TRAINING IN THE AUTO – TRUCK INDUSTRY:

E-Mail. Ed I wanted to send update about that E-Town, DANA plant
that you visited a few years ago. As you know on your first visit, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour, and over 90% of the frames required extensive weld rework.

Thanks to your Robot Weld Process Controls – Best Practices Training program, and your process and consumable recommendations, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks! Ryan Good.
A grateful engineer, and a grateful DANA Corporation.

Note The DANA corporation is a tier one supplier and a world leader in the supply of drive line products such as frames, axles, drive shafts, and transmissions for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.

WELD PROCESS CONTROL TRAINING FOR ANY WELD SHOP USING MIG – FCAW.

E-Mail. Dear Ed, I want to let you know that by using your MIG – Flux Cored weld process control – best practice methods in our plants, we have now dramatically improved our weld quality – productivity and reduced our labor – filler metal costs by approx. 45%. We intend to utilize your training program in all our plants.
Lawrence Bower CWI/CWE.
Chief Welding Engineer.
NCI Group. Houston TX.


Mangers, please be aware that Universities, Colleges & Training Facilities, don’t provide the weld industry with the weld process control – best weld practice resources that are provided here. If you feel you are on top of your processes try the following weld quiz.

Ed’s MIG Weld Process Controls & Best Practice Quiz.

Ed’s Flux Cored Weld Process Control & Best Weld Practice Test

BELOW: A FEW OF THE ROBOT WELD QUALITY PRODUCTIVITY BENEFITS THAT COMPANIES
HAVE ATTAINED FROM MY WELD PROCESS CONTROLS – BEST PRACTICE RESOURCES:

 

Dana USA.

E-Mail from R Good at Dana USA.
Truck frameJan 2007: Ed. I wanted to send update about that E-Town DANA plant that you visited a few years ago:,

As you know on your first visit to this plant, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour and over 90% required extensive weld rework.

Thanks to your Robot Weld Process Control Best Practice Training program, and the weld process and consumable changes that you recommended and we implemented, the robot weld results from our employees today are staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily now attain our average goal of one frame per-minute. We have had two recent weld audits, one audit found a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of our Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks from Ryan Good, a very grateful DANA engineer and thanks from a grateful DANA Corporation.

Note DANA is a tier one supplier and world leader in the supply of drive line products such as axles, drive shafts, and transmissions and power technologies for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.


Johnson Controls Mexico: 

When the new VW Beetle was introduced, the contract for the Beetle  seat frames was given to Johnson Controls (JC) Mexico. For many months, JC was  having problems with it’s new robot Beetle seat welds. These welds were being carried out in accordance with the robot weld requirements from VW Germany. The German MIG parameters were too low effecting both the weld quality and robot productivity. I was asked by JC to help resolve their many robot issues. In 3 days at the Mexican plants I completely changed the robot weld program and the weld transfer modes and parameters. I increased the daily robot shift weld production by 40% and eliminated the weld rework. As for the weld quality I attained. In 1999 – 2000,  the USA Insurance Institute for Highway Safety, rated the car seats that I provided the data for, as the most durable of all in the small cars they had ever crash tested.

Viza Spain:

Viza makes auto – truck  seats for Toyota, Renault, Citroen, BMW and others. The president of Viza requested that I come to Spain which I jumped at as it was certainly much more pleasant than going to Detroit. He wanted me to resolve his companies robot seat welds and  establish my  Best Weld Practices / Robot Process Controls for his companies new  robot MIG weld lines. In two weeks I established highly success robot weld quality – productivity results. And then trained the Spanish employees with my robot MIG weld process control  training program. A few years later I was requested to return by Viza for the start up of two more new plants, one in Spain and the other in Eastern Europe.

Tenneco USA

E-Mail. Ed as you know Tenneco has plants all over the world. We and especially Monroe Shocks which is one of our companies have been very enlightened by your ” Robot MIG Weld Process Control Training Resources.

Regards. Tom Plummer: Tenneco. USA. 2007.

Caterpillar and Elgin USA.



Caterpillar Elgin SweeperE-Mail: Hello Ed. In the past I purchased your manual MIG welding process control – best practice training resource for Caterpillar plants and more recently I purchased your Robotic MIG process control training package for Elgin Sweeper Company here in Illinois. Em your programs worked wonderfully at Caterpillar. We were very successful after implementing your Best Weld Practices and Process Control Training. Thanks to your resources and equipment and consumable recommendations, our manual and robot MIG weld quality – productivity results are now outstandingAll the best EC. Joe Cukierski…Weld Manufacturing Engineer.
Elgin Sweeper Company.

The industry is not relevant. There is only one way to weld.

NUCLEAR – OIL – AEROSPACE – POWER – DEFENSE INDUSTRIES ALL BENEFIT FROM WELD PROCESS – CONTROLS – BEST WELD PRACTICE EXPERTISE.

Nuclear subOil drilling deep sea rigDefense industry spy plane

Over the years Ed has been asked by the following industries to improve their manual / automated weld quality and productivity.

Nuclear, Defence, Oil, Nat Gas, Power, Sub Sea, Ship Building and Medical equip applications. She also was asked to improve the GTAW weld quality on USA Fighter Jets engine cast bodies and requested to establish robot MIG weld data for complex boiler tube to headers (ASME, power plants).

Ed has always provided optimum weld results often with unique weld solutions for any application she has been asked to work on. Her hands on approach combined with her weld process controls – best practices and follow up training programs always enables the best possible weld quality / productivity results.

No welding job is too big and no alloy too complex, when those responsible for the plants weld decisions truly understand the weld processes – consumable they use.

From setting optimum welds for the worlds largest producer of power plant boilers or providing the robot welds for the small Caterpiller trucks below, its all the same to Ed. The botton line is when you have weld process control expertise you can on any application produce the highest possible weld quality at the lowest possible weld costs

Ed established the original ABB robot MIG Process Control and Best Robot MIG Weld Practice data for the worlds largest trucks made by Caterpillar

Ed established the original ABB robot MIG Process Control and Best Robot MIG Weld Practice data for the worlds largest trucks made by Caterpillar.

2016.. For almost three decades, the majority of MIG weld equipment purchased has been made up of useless circuit boards that provide electronic bells and whistles which provide no weld benefits for steel and alloy steel welds. This mass global weld shop acceptance of the diffiicult to repair, often less than durable, costly MIG equipment technology is again a reflection of the lack of process expertise and sales reliance found throughout the global MIG weld industry.

Welding salesmen provide a crutch for the inexperienced weld decision makers at the plants

If you want Bovine Fecal Matter you know who to call and its not Ghost Busters. The good thing about that weld salesman apart from buying lunch and supplying donuts, he often provides a crutch for the inexperienced weld decision makers at the plants.

He looks the part. but
you know what’s missing.

TAKE CONTROL OF THE PROCESSES THAT CREATE YOUR PROFITS

FOR GOD SAKE ITS YOUR WELD SHOP, TAKE CONTROL OF THE PROCESSES THAT CREATE YOUR PROFITS.
If you were to examine the resumes of the typical weld distributor reps or the reps from Lincoln, Miller, ESAB, Panasonic, Fanuac, Motoman or Cloos, you would likely find that in most instances, these individuals have never run a weld shop, yet these personnel will be ready to provide all types of weld / application advice, and these characters may become the most widely used process resource for the inexperiences weld shop managers, engineers and supervisors.

LOOKING FOR EXPERIENCED PRACTICAL ADVICE ON WELD EQUIPMENT AND CONSUMABLES. I HAVE AN EXTENSIVE EVALUATIONS OF WELD EQUIPMENT / CONSUMABLES AT THIS SITE AND ALSO THIS INFO IS PART OF MY PROCESS CONTROL – BEST PRACTICE TRAINING PROGRAMS:

WE ALL KNOW THIS.. MILLIONS OF DOLLARS ARE LOST DAILY IN WELD SHOPS ESPECIALLY WHEN THEY PUT THE WELDS ON, THEN GRIND THE WELD OFF. In the global weld shops, in which the front office personnel lack the process expertise to take full ownership, accountability and responsibility for the MIG / Flux Cored equipment and consumables utilized, you will find especially with the weld personnel that play around with the weld controls, that a critical tool required is called a GRINDER. In these weld shops, one job thing that the management and supervision will do well, is to ensure that their play around welders do not run out of the never ending grinding discs that are required..

 

If it takes anyone more than 5 minutes to work out the cost of any MIG – Flux Cored or TIG weld, they don’t have weld process control expertise.


If it takes anyone more than 5 minutes to work out the cost of any MIG - Flux Cored or TIG weld, they don't have weld process control expertise

WHILE MIG – FLUX CORED WELD PROCESS AND WELD COST CONFUSION IS THE NORM FOR THE MAJJORITY OF GLOBAL PLANTS, IT’S ALSO A GREAT OPPORTUNITY FOR INTERESTED MANAGEMENT TO START ON A PATH TO PROVIDING EXTENSIVE WELD COST REDUCTIONS AND INCREASED WELD PROFITS.

 

THE COMMON FOCUS ON WELD COSTS IS USUALLY IN THE WRONG PLACE.. In the majority of MIG – Flux Cored weld shops, the management “focus will usually be on the costs of the weld consumables utilized” consumables such as the weld wires, the gas mixes and of course those costly grinding wheels. In North America, the MIG – Flux Cored steel wires and gas mixes typically account for only 15 – 18% of the actual daily weld costs.

If front office personnel are not focussed on the weld knowledgable required for weld process optimization, it’s impossible for these personnel to fully control their weld costs, and therefore it’s impossible for their company to optimize the profits that are attainable from the weld shop.

What other tech industry do you know that when they cannot ANSWER A WELD PROCESS QUESTION OR PROVIDE A WELD RESOLUTION, THEY PICK UP THE PHONE AND ASK A SALESMAN?

Don't ask a salesman for weld advice.

YOU WANT WELD ADVICE? YOU COULD ASK A USED CAR SALES MAN, A SALESMAN WHO SELLS FURNITURE AT SEARS, OR A WELD SALESMAN, IN MOST INSTANCES IT REALLY MAKES LITTLE DIFFERENCE AS THE BOVINE FECAL MATTER IS SURE TO EVENTUALLY FLOW. THE ONE DIFFERENCE IT DOES MAKE, IS THERE WILL ALWAYS BE A STEEP PRICE PAID FOR A COMPANY THAT HAS WELD DECISION MAKERS THAT NEED THAT OUTSIDE CRUTCH.


IN A WELD SHOP IN WHICH A GOOD PORTION OF THE MANAGERS, ENGINEERS, SUPERVISORS AND TECHNICIANS
OFTEN HAVE TO RELY ON SALESMAN FOR PROCESS GUIDANCE, IT SHOULD BE NO SURPRISE TO FIND;

[] THE WELD SHOP INNUNDATED WITH WELD PROCESS MYTHS – HYPE AND CONFUSION.

[] A VARIETY OF POOR UNECESSARY WELD EQUIPMENT LOADED WITH USELESS BELLS AND WHISTLES.

[] A WELD SHOP THATS FOREVER LOOKING FOR A MAGIC SOLUTION FROM ONE OF THE AVAILABLE
AND MOST OFTEN USELESS 40 MIG GAS MIXES.

[] A WELD SHOP THAT ALWAYS HAS MORE WELD PROCEDURES THAN IT REQUIRES.

[] A WELD SHOP IN WHICH THE TECHNICAL PEOPLE HAVE TO WORK EXCESS HOURS AS THEIR COMPANY IS ALWAYS IN THE FIRE MANS MODE AND THE TECS DONT HAVE THE EXPERTISE NECESSARY TO CREATE A CALM CONTROLLED ENVIROMENT.

[] A WELD SHOP IN WHICH WELD REWORK / REJECTS ARE CONSIDERED A NORMAL PART OF PRODUCTION.

[] A WELD SHOP THAT USES THE WRONG SIZE MIG WIRES, OR COSTLY CORED WIRES WHEN THE LOWER COST CORRECT SIZE MIG WIRES COULD HAVE BEEN MORE PRODUCTIVE.

WELD SHOPS SUCH AS THESE HAVE TO PRODUCE EXTENSIVE WELD COST REPERCUSSIONS. THEY ARE SHOPS THAT SHOULD ALWAYS LOOK OVER THEIR SHOULDER FOR WELD FAILURE LIABILTY CONSEQUENCES. THEY ARE WELD SHOPS IN WHICH THE MANAGEMENT / SUPERVISION NEED TO GET A GRIP. THE GOOD NEWS FOR THESE SHOPS IS THERE WILL ALSO BE GREAT POTENTIAL FOR WELD QUALITY IMPROVEMENTS AND WELD COST REDUCTIONS.

We need to optimize our welding process

YOU CAN NEVER REPEAT THIS ENOUGH: Why would any weld shop mgr. engineer, supervisor, technician or QA person, that is hired in a position of weld responsibility, allow the weld personnel they work with to “play around” and not optimize the daily MIG – Flux Cored weld? . Especially when for the costs of a few dollars, they could provide them selves and their employees with the process control programs at this site.

Best weld practices and weld process contols

SLOW AND PAINSTAKING EVOLUTION IN
THE GLOBAL WELD INDUSTRY.

The slow evolution of the global weld industry

ALL YOU NEEDED TO KNOW ABOUT THE STICK (SMAW) WELD PROCESS. AND EQUIPMENT, WAS SELECT THE RIGHT ELECTRODE, TURN THE WELD CURRENT UP OR DOWN AND APPLY THE REQUIRED SKILLS FOR THE JOB, STICK WELDING LIKE TIG WERE PROCESSES IN WHICH THE FOCUS WAS ON THE WELDER SKILLS.

IN CONTRAST TO STICK AND TIG, MIG – FLUX CORED HAVE NOTHING IN COMMON. MIG PROVIDES DIFFERENT WELD TRANSFER MODES WHICH ARE DRAMATICALLY INFLUENCED BY THE CONSUMABLE SIZES AND GAS MIXES USED, THESE ARE PROCESSES IN WHICH THE WELD PERSONNEL AND WELD MANAGEMENT BENEFIT FROM PROCESS CONTROL / BEST PRACTICE EXPERTISE.

THE COMMON GLOBAL WELD SHOP LANGUAGE. .

WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT?
GIVE ME A MINUTE TO PLAY AROUND WITH THE WELD CONTROLS.
JOE’S EXPERIENCED HE’S BEEN WELDING FOR TWENTY YEARS.
CAN YOU GET FRED THE WELD SALESMAN HERE ASAP?.
WHAT JOB DESCIPTION?
WE NEED TO TRY THAT NEW GAS MIX.


In weld shops where so called many “experienced” weld personnel will daily ply their trade, weld decision makers may be surprised to find out that their welder skills and their years of weld experience are only a small requirement in attaining weld process optimization.

The above reality is quickly revealed when the MIG welding robots come into the weld shop and the so called experienced weld personnel quickly learn how little they know about the subject of providing MIG or Flux cored weld process controls.

PROCESS CONTROL EXPERTISE PROVIDES MORE THAN WELD QUALITY PRODUCTIVITY IMPROVEMENTS.
Perhaps you are a manager, engineer, supervisor, technician, or a weld person that believes your career weld prospects could improve with Weld Process Control – Best Weld Practice knowledge. Or perhaps you are a manufacturing engineer, supervisor, technician or god help us a manager that wants to optimize your companies manual or robot, MIG – FCA weld quality and productivity. If so please take a moment to review my MIG and – Flux Cord Weld Process Controls and Best Weld Practice resources.

The following is what you will find at this weldreality Home Page.

[] MILLIONS OF DOLLARS WASTED DAILY: You may want to know the reasons the global weld industry annually wastes hundreds of millions of dollars on the purchase of useless, two and three part gas mixes, costly flux cored and metal cored wires, and costly MIG equipment that’s mostly loaded with useless, electronic bells and whistles.

[] WHAT SKILLED WELDER SHORTAGE?: In the fifty years i have been in this business, I have trained > 5000 personnel in how to optimize MIG – flux cored welds. Myself or the trainers – engineers or other personnel that I trained, could take an individual who has never welded, and using my simplified weld process training resources in approx. 40 – 60 hrs, have them pass any MIG – Flux Cored, AWS – ASME – API or ABS code weld qualification requirement. With this in mind you cannot pick up an engineering magazine in the last decade, and find some inexperienced weld shop executive complaining about their concerns for finding skilled MIG or Flux Cored welders.

[] WHEN MIG – FLUX CORED WELD COSTS ARE NOT FULLY UNDERSTOOD, HOW CAN A WELD SHOP PRODUCE THE LOWEST WELD COSTS AND MAXIMIZE IT’S DAILY WELD PROFITS?: If the weld decision makers are not optimizing their weld processes to attain the full weld quality – productivity potential, they simply cannot be in control of their daily weld costs. In the majority of global weld shops, you may not want to go looking for anyone in weld supervision or management that could in two minutes work out the real cost of their most common MIG or flux cored welds.

Note: My process training resources simplify how to figure out weld costs

2016: For almost two decades, most of the global high tech industries and weld shops have been stuck in the welding dark ages..

2016: When will managers / engineers and QA personnel wake up to the fact that in the last two decades the important TIG process evolved into a far superior process called TIP TIG?

THE LACK OF WELD PROCESS KNOWLEDGE – EXPERTISE DOES NOT JUST APPLY TO MIG AND FLUX CORED WELDS.
2016: The TIG (GTAW) process has always been considered the process of choice for code, high quality welds and especially with welds on costly alloy applications. The TIG process with deposition rates typically lower than 1.5 lb/hr is also painfully slow process. The slow TIG weld travel rates will often create excess weld heat something few alloys benefit from. The traditional manula TIG process is considered the most difficult process to learn especially with pipe welds. As a result of the high skills required TIG welders are often the highest paid welders with a process that each hour delivers poor weld deposition rates.

The traditioonal TIG weld quality and the part / weld metallurgy and productivity is dramatically improved with the much easier to use TIP TIG process. TIP TIG is a process invented in Austria. This is a process that I along with my business partner Tom, introduced to the USA, Canada and Australia many years ago.

TIP TIG dramatically reduces the skills required and is simple operate especially on all position pipe welds.
TIP TIG enables a 200 – 500 percent increase in hourly weld productivity, imagine the reduced labor costs.
TIP TIG provides higher energy, agitated weld pools that provide unique weld quality benefits.
TIP TIG with higher deposition and EN polarity, provides welds / parts with the lowest possible weld heat.
TIP TIG is not only a great manual process it provides numerous automated – roboit TIG benefits.

It’s again a sad reflection that in a high tech country like the USA, few managers or engineers in the defence, aerospace, energy, power, oil, nuclear companies who rely on the TIG process, will have heard about a weld process that soon will have been around for two decades.

WELD INSPECTORS OFFER LITTLE VALUE TO THE WELD SHOP IF THEY LACK THE WELD PROCESS CONTROL – BEST WELD PRACTICE EXPERTISE THAT CAN HELP PREVENT WELD DEFECTS AND THE COSTLY WELD REWORK.


Anyone with a few days training can judge the external quality of a weld and in a white coat walk around the shop providing criticism. Also the AWS will ensure that anyone with a little weld shop experience and more than a thousand plus dollars for its none profit vault in Miami can become an AWS weld inspector.

The question management needs to ask, apart from the crutch they provide, what benefit can be derived from these personnel in the weld shop?


WELD INSPECTORS… IN MOST GLOBAL PLANTS, A DAILY FUNCTION FOR WELD INSPECTORS IS TO SEE THAT THE WELDS ARE MADE TO CODES / SPECIFICATIONS IN WHICH THE CODE BODY TYPICALLY CLEARLY SPELLS OUT ON THE FRONT PAGE OF IT’S SPEC, THAT IT TAKES NO RESPONSIBILTY FOR THEIR WELD INFORMATION IN THE RECOMMENDATIONS PROVIDED. ANOTHER DAILY FUNCTION OF THE WELD INSPECTOR IS TO DO A VISUAL INSPECTION AND IDENTIFY UNNACEPTABLE WELD DEFECTS, WHICH THEY OFTEN DO AFTER THE PARTS WELDED ARE COMPLETE.

WELD INPECTION LOGIC: . A GOOD MANAGER WORTH A PINCH OF SALT WOULD ENSURE THEIR WELDERS WOULD NOT WALK AWAY FROM A PART THAT REVEALS ANY VISIBLE WELD DEFECTS.

WELD QA MANAGEMENT LOGIC: WHEN WELD INSPECTORS ARE A NECESSITY, IT WOULD BE LOGICAL FOR THE QA MANAGER TO PROVIDE THERE PERSONNEL AND THEMSELVES WITH SOMETHING OF REAL VALUE FOR THEIR ORGANIZATIONS ITS CALLED, WELD PROCESS CONTROL – BEST PRACTICE TRAINING.

NOT PROVIDED ELSEWHERE: MY PROCESS CONTROL SELF TEACHING / TRAINING PROGRAMS ARE NOT PROVIDED BY ANY CODE ORGANIZATIONS, BY ANY COMMUNITY COLLEGES OR EVEN BY THE GLOBAL UNIVERSITIES THAT TEACH WELD ENGINEERS.

COST EFFECTIVE INSPECTION: WITH A FEW HOURS, MY PROGRAMS WOULD GIVE THE INSPECTION PERSONNEL TO EXPERTISE NECESSARY TO HELP PREVENT WELD DEFECTS, WHICH HAS TO BE A MUCH MORE COST EFFECTIVE APPROACH THEN SIMPLY FINDING WELD DEFECTS.

WHY GET PISSED OF AT THE MESSENGER? AS FOR THOSE WELD INSPECTORS THAT SIMPLY LIKE TO CRITICIZE WELDS WITHOUT HAVING PROCESS SOLUTIONS, THOSE ARE WELD INSPECTORS WITHOUT AN INTEREST IN WELD PROCESS CONTROLS / WELD BEST PRACTICES WITH THE PROCESSES THAT THEY AND THEIR COMPANIES DERIVE A LIVING FROM.
FROM MY PERSPECTIVE, AS WE USED TO SAY IN MANCHESTER, UK, 
THEY ARE AS AS USELESS AS A FART IN THE WIND.

Check out all my Process Controls – Best Weld Practice Self Teaching / Training programs..

The salesman, always a valuable CRUTCH for
many in the weld shop FRONT OFFICE..


.


THE FIRST STEP TO CUTTING OUT THE COMMON BOVINE FECAL MATTER AND WELD PROCESS MYTHS THAT PREVAILS IN MANY WELD SHOPS, IS FOR SOMEONE IN 
THE FRONT OFFICE TO RECOGNIZE WHAT IS WELD REALITY AND WHAT WELD PROCESS CONTROLS AND BEST WELD PRACTICES ARE.

As in 1985, as it still is three decades later in 2016, the best possible, manual and robot “carbon or alloy steels” MIG welds, simply require a low cost, traditional CV MIG weld power source, a two part argon 2 – 20% CO2 gas mix, and the selection of the “correct” type and size of MIG wire. With the robot welds of course an important requirement was the power source has a control so it could communicated with the robot. and the individual responsible for the robot cell had robot programming training. Also and mostly overlooked, this individual was provided with MIG Weld Process Control & Best MIG Weld Practice Training”.

With robot welds, in the last two decades, robot manufactures have strived to improve both their weld soft ware and robot cell hard ware and also tried to improve the robot to power source communications. Now in 2016, in most robot cells, we have unnecessary, highly sophisticated, electronic MIG equipment with a built in interface. From my five decades of MIG weld equipment evaluation, in general, the majority of the electronics introduced into today’s most sophisticated pulsed MIG equipment have created NO STEELS OR ALLOY STEELS, WELD QUALITY – PRODUCTIVITY BENEFITS. However these electronics have created numerous headaches as discussed at this site in the MIG equipment, pulsed process and robot weld sections. See all weld programs..


ED AT A TIER ONE CAR SEAT MFG IN SPAIN. HE HAD TO WORK WITH THE USELESS ELECTRONIC BELLS AND WHISTLES ON THE MILLER MIG POWER SOURCE THAT WAS IN THE ROBOT CELLS. THIS POWER SOURCE AS IT HAD DONE FOR YEARS PROVIDED NO WELD BENEFITS ONLY WELD ISSUES FOR THE SPANISH CAR SEAT MFG AND OTHERS.

So that costly robot cell sits there with it’s electronic pulsed MIG power source which is typically loaded with useless, electronic bells and whistles. This of course pushes up the MIG weld equip prices, reduces the MIG equipment durability, adds to the MIG equip repair complexity, and brings another weld transfer mode to a shop that rarely has figured out how to optimize the other two weld transfer modes, short circuit and spray.

As a purchaser of robot weld equipment, reading this will do little to change things, I simply want you to be aware that you don’t have to buy into the electronic MIG equipment BS that proliferates. Also when managers do get sold on this type of equipment they then tend to purchase this costly and again unnecessary weld equipment for the manual welders in the shop. The weld reality is this. I could demonstrate in approx. 10 minutes that a CV MIG power which usually costs <$3000, can for steel and alloy steel welds, provide the same quality and often higher weld productivity that that attained from the electronic MIG units that costs three to five times as much.


WELD REPAIRS. A SUBJECT RARELY TALKED ABOUT, AND USUALLY ABUSED IN THE AUTO – TRUCK INDUSTRY.

One way to benefit from the my process control self teaching / training programs. Lets say you have a large number of robots and in each robot cell there was either an expensive Fronius, Miller or Lincoln Power Wave MIG unit. Lets also say you were using either an 0.045 – 0.052 or 0.062 (1.2 – 1.4 – 1.6 mm) MIG wire. It’s very common with auto part suppliers (big and small), that when they order robot cells to also order the same or similar MIG equipment and consumables for their weld repair stations. Frequently they will use the same size MIG weld wire in the repair station as used on the robot lines. We have potential here on the next robot order to lower the weld repair costs, and also improve the repair weld quality.

As most of you are aware, most auto part weld repairs are made in small weld areas with very short arc on times. Most MIG weld on weld repairs will require high energy welds. Using the smaller 0.035 (1mm) wire allows higher current density. This wire can be set for low / high end spray settings, or welding gaps, with high end short circuit settings. When set correctly the settings should not create weld spatter concerns. With the 0.035 wire, the best possible MIG power source is a low cost 250 amp CV MIG power source, (approve. $2000 – $3000, wire feed included). This power source, wire size combination will provide with the majority of weld applications superior weld results than that which can be attained with the much higher cost pulsed MIG units and the larger MIG wire diameters. Yes a little MIG process training is required (should be provided any way). The training typically takes a day, but the savings can be considerable, the weld repairs more meaningful and weld management is doing it’s job. Of course that process control – best weld practice training will also ensure the highest possible robot weld quality and productivity with the least amount of robot weld repairs and down time.

Note: In the 1990s, while I was the Robot Weld Manager for the North American ABB Robot Weld Div, Miller Electric senior executives informed ABB management that they wanted to stop selling their Delta Weld 450A power sources, they were complaining about their costs to build. The Delta Weld has been for decades and still is in 2016, the best available global MIG power source. For years we had in the ABB robot weld division been highly successful with hundreds of applications with this power source which for robots was sold with a separate electrical robot interface. The Miller executives wanted use to use their much inferior electronic Invision or Maxtron power sources, (cant remember at this time which one). The Miller Delta Weld units were very well built, easy to repair and from a weld performance perspective this equip provided the optimum slope, (volt – amp curve) for the majority of weld applications. While I was the ABB robot weld mgr, I let Miller know these units would always be my first choice for any manual or robot MIG application. I advised the ABB CEO to inform Miller that if we had to stop using their superior CV Miller Delta Weld equip for their unstable, erratic, poor performing electronic Invision or Maxtron power sources, then we would likely have to look to another MIG equipment manufacturer to supply us with MIG equipment.

In the 1990s, ABB was the prime source for robots to the world’s largest robot user, a tier one company called A.O.Smith. With over 1000 robots in it’s plants, this companies engineers (many attended my robot process control training program) and myself were well aware of what MIG power source was optimum for robot steel applications. The Miller Delta Weld with its optimum slope was the perfect MIG power source in the 1990s, and is still the best MIG power source available for manual and automated steel MIG welds in 2016.

THE WELD REALITY.. IN 2016, with the general lack of MIG process expertise and the lack of ability to judge the performance requirements of an optimum MIG power source, unfortunately most global robot MIG cells end up with inferior performing, over priced MIG power sources that typically will be full of useless electronic bells and whistles that offer have a poor slope and provide no weld benefits. This inferior weld equipment wil however shorten the equipment life and when issues occur with those useless electronics the result is confusion for the maintenance dept.


In the 1990s, my robot weld process controls were used to make these 3/8, (10mm) single pass, “untouched” robot fillet welds using regular low cost CV MIG equipment and consumables. No BS – No Bells and Whistles – No magic three part Gas mixes and No costly Cored Wires.



.

The selection of optimum Robot MIG weld data, (without playing around with the controls) is made simple with my Robot Best Weld Practices and Weld Process Control Training – Self Teaching / Training Programs.


MIG POWER SOURCE CONSIDERATIONS THAT POSSIBLY SOME MGR MAY BE INTERESTED IN.

I would guess with the gas shielded flux cored process, that the majority of consumables used in 2016 were developed and tested on traditional CV MIG equipment that has hardly changed in 60 years. This important process daily accounts for approx. 10 – 15 % of the global welds produced. What most people who make welding decisions are not aware of is when you use;
[1] Multi-Process MIG equipment,
[2] Inverters,
[3] Pulsed MIG equipment for gas the shielded flux cored welds, you are using inferior equipment that does not provide the the same slope output as conventional CV units. Usually with these 3 types of weld equipment, typically for a given wire feed setting you will get less current than that attained with a good CV unit. This means the newer equipment could be contributing to less weld fusion, increased slag entrapment and increased porosity.

THE USA OR CHINA. WELD BS IS WELD BS....Chinese mfg.. companies seem to have a difficult time making Wallmart steel can openers or steel nails that don’t bend under a hammer blow. So when Chinese construction companies are asked to build any large scale projects involving extensive use of steels and welds, no one should be surprised if the responsible CHINESE ENGINEERS ON THE CONSTRUCTION PROJECTS EVER REPORT THE “REAL WORLD WELD QUALITY RESULTS”.

The sad, apathetic, engineering – weld issues that I saw with the cored process during the weld construction at the Bejing Olympic Stadium (below), happens every day on large construction projects and ship yards around the globe.

For those that may have wondered why the modern day buildings collapsed during the small earth quake at Northridge California, take a time out. click here, and find out how the management / engineering lack of self shielded flux cored weld process expertise combined with ignorant politicians and companies that do no take responsibilyu can create legal liability diversions, and as in this remarkable case, actually create new, ridiculous FEMA weld specifications..

.

Will the extremely poor quality cored welds that were made on the construction of the Beijing, Birds Nest, Olympic Stadium, mean that one day this unique designed steel structure will turn into a Spiders Web Trap for the stadium spectators?

GREAT STADIUM DESIGN, PATHETIC CHINESE CONSTRUCTION PRACTICES AND SOME OF THE WORLD’S WORSE WELDS..

Written by E Craig.
Posted. www.weldreality.com.
Aug. 2. 2008.

The five hundred million dollar, Beijing, Olympic stadium was built on top of an earth quake fault. The steel stadium is wrapped in a unique designed, high strength steel cocoon that weighs approx. 45,000 tons. While the world’s focus was on the artistic design of this stadium, my focus was on the sad weld engineering practices that were used to build it.

At the end of July, two weeks before the 91,000 seat stadium was ready to host the 2008 Olympics, I sat in front of my TV and watched a Discovery Channel program about the stadium construction. The steel Bird’s Nest design is without question a steel wonder to behold, however having a more than slight interest in welding fabrication you know where my focus was. While I watched the TV show that showed the construction, I did not like what I saw that was going on with the on site welders and their welds and I certainly knew that what the chief engineer at the site was saying about the welds, was simply a load of rubbish.

May. 2009. Beijing Update: Check out what’s happening to this Chinese stadium, nine months after Ed wrote his opinions on the poor welds and construction at the Birds Nest stadium.


I HAVE A QUESTION FOR MILLER – LINCOLN – ESAB AND PANASONIC MANAGEMENT, I WONT HOLD MY BREATH WAITING FOR A REPLY? 

So the weld equipment mfg. promotes and sells useless electronic BELLS AND WHISTLES IN THEIR MIG EQUIPMENT. The weld equipment mfg. is aware (or is not aware) that their power source electronics offers no real world weld benefits, or that the power source electronics is negatively influencing the weld equipment durability and the end users MIG or FCA weld quality / productivity. These guys rarely if ever recall this MIG equipment, or notify the end user. Should the purchaser of the weld equipment sue the weld equipment mfg? JUST ASKING.

2015.. Major MIG equipment manufacturers like MILLER, ESAB, LINCOLN AND PANASONIC CONTINUE TO ATTAIN EXTENSIVE PROFITS FROM AN INDUSTRY IN WHICH MANY SEEM HAPPY TO PAY AN UNNECESSARY PREMIUM TO PURCHASE COSTLY, UNNECESSARY, ELECTRONIC PULSED MIG EQUIPMENT, WHICH FOR THE THREE DECADES THAT I HAVE EVALUATED IT, HAS TYPICALLY BEEN LOADED WITH USELESS, INEFFECTIVE, ELECTRONIC BELLS AND WHISTLES.

Note: I have also evaluated MIG gas mixes for decades, and have never seen a reason to justify the purchase of a three part gas mix for steels, low alloy steels or for stainless applications. See my MIG gas section.

Rather than wasting money on the costly $5K to $25K electronic MIG equipment, If instead, weld shops would spend approx. $300 and utilize my weld MIG & FLUX CORED WELD PROCESS CONTROL – BEST PRACTICES RESOURCES, these weld shops would then have the process controls keys necessary to attain the full potential from the much lower cost CV equipment and consistently attain optimum, manual and automated MIG and flux cored weld quality and productivity at the lowest labor costs.

It was my job as the Corporate Training & Weld Product Manager with companies such as Linde (Praxair), Airgas, AGA and Liquid Carbonic, to test MIG weld equipment and the MIG and flux cored weld consumables that were available in North America and from around the globe. Of my 50 years in this business, I did the product evaluation for approx. 30 years.

Today, as many of you are aware, in 2105, you can pay $3500 to $5000 for a traditional CV 350 – 450 Amp. MIG power source and wire feeder, or you can pay approx. $6000 to >$20K for Pulsed MIG equipment.

ALL IT TAKES IS APPROX. 10 MINUTES PLUS A WELD SHIELD AND OF COURSE MIG PROCESS CONTROL EXPERTISE, TO PROVE THE ABOVE WELD EQUIP FACT:

For weld shop management that has no wish to waste their potential profits in purchasing costly pulsed MIG equipment, or from unnecessary weld rework and poor weld productivity, the weld reality is this. Using my MIG – Flux Cored Process Control – Best Practices and Self Teaching – Training resources available here, there will be many cost benefits possible for the weld shop. For example, in contrast to the costly, pulsed MIG power equipment, when welding carbon steels, alloy steels and stainless weld applications with the much lower cost, easier to maintain, easier to operate, more durable, conventional, CV. MIG equipment , the weld shop could attain greater MIG and Flux Cored weld productivity with superior weld quality (superior fusion – less porosity) on all applications > 4 mm.

MIG WELD EQUIPMENT FACT:

Before your company wastes thousands of dollars on pulsed MIG equipment, remember if you wish to attain optimum MIG or Flux Cored weld quality – productivity on carbon steels & alloy steels, gauge to any thickness, simply requires CV. MIG equipment. This equip should in North America cost approx. $3500 to $5000 for ,350 to 450 Amp CV MIG power source. You may want to check out the MIG equipment part of this site to see the weld equipment that I recommend, and the weld equipment that makes me want to chew too many TUMS.

When employees lack MIG – Flux Cored, Weld Process Controls and Best Weld Practices expertise, weld shops will unfortunately, daily waste many $$$ on the following weld issues.

[1] MIG WELDS THAT ARE MADE DAILY WITH PROCESSES AND CONSUMABLES THAT HAVE BEEN AROUND FOR DECADES, SHOULD NOT REQUIRE WELD REWORK OR GRINDING.

[2] MIG WELD SPATTER COSTS GLOBAL WELD SHOPS BILLIONS OF DOLLARS ANNUALY TO REMOVE, YET WHEN WELD PERSONNEL HAVE WELD PROCESS EXPERTISE, SPATTER SHOULD BE MINIMUM.

[3] IN THE MAJORITY OF WELD SHOPS, BOTH THE MANUAL AND THE ROBOT WIRE FEED / WELD DEPOSITION RATES RELATIONSHIPS ARE RARELY UNDERSTOOD, AND THEREFORE WELD DEPOSITION RATE POTENTIAL IS RARELEY ACHIEVED.

WELD DEPOSITION RATES ACCOUNT TYPICALLY FOR APPROX. 80% OF WELD COSTS. WHEN WELDS ARE NOT AT THE HIGHEST POSSIBLE DEPOSITION RATES, MUCH HIGHER HOURLY WELD LABOR COSTS ARE BEING GENERATED. WITH MY TRAINING PROGRAM, THE MAJORITY OF WELD SHOPS WILL HAVE THE POTENTIAL TO REDUCE THE WELD LABOR COSTS IN THE 20 TO 70% RANGE.

[4] PAYING UNNECESSARY HIGH MIG WELD EQUIPMENT COSTS TYPICALLY BY PAYING FOR USELESS BELLS AND WHISTLES, IS NOW THE NORM THROUGHOUT THE GLOBAL WELD INDUSTRY.

[5] MANY COMPANIES WILL PURCHASE UNNECESSARY CARBON STEEL METAL CORED AND FLUX CORED WIRES, WHILE IN MANY INSTANCES, MUCH LOWER COST MIG WIRES WOULD DO THE SAME JOB.

[6] MANY COMPANIES WILL PURCHASE USELESS THREE PART GAS MIXES THAT CONTAIN OXYGEN WHICH BY THE WAY IS DETRIMENTAL TO MOST MIG WELDS. SAVINGS ARE ATTAINED BY USING LOWER COST, TWO COMPONENT ARGON – 10 TO 20% CO2, MIG GAS MIXES.

[7] MANY COMPANIES WILL PURCHASE ADDITIONAL ROBOTS WHEN THEY HAVE NEVER ATTAINED THE FULL WELD PRODUCTION OR QUALITY POTENTIAL OF THEIR EXISTING ROBOTS.

ALL OF THE ABOVE, ARE ADDRESSED WHEN THE WELD DECISION MAKERS HAVE THE WELD PROCESS CONTROL EXPERTISE THAT IS AVAILABLE IN MY TRAINING RESOURCES.


MIG Gas Mix Selection has for decades been surrounded by weld process / application confusion, process myths and typically by marketing induced Bovine Fecal Matter Sales Adjectives. Weld shops buy into the sales BS gas adjectives with their 40 plus gas mixes and this again over the decades has had tremendous weld cost and quality consequences for the global MIG weld industry.

Note: Four of the MIG gas mixes that I developed are now some of the most popular sold in North America and also I wasted 2 years of my life helping write the AWS MIG Gas Specifications.



The good news for the weld industry. When you find management, engineer and supervision weld process ignorance, apathy or confusion, you will typically find that a work shop enviroment in which it’s easy to quickly create extensive weld improvements, enabling extensive weld cost savings. E Craig in 1986…….


It’s a weld reality, that the global weld industry could save hundreds of millions of dollars daily if many of the managers, supervisors and engineers that influence the daily weld decisions, learnt to to take “full ownership and responsibility” of the weld equipment, processes and the weld consumables that are typically essential to the success of their organization.

It’s a common sense statement, that in their role as a professional, that any weld decision maker should be capable of managing or supervising a weld shop without weld advice from a weld sales rep. And yet in many advertisements you will see for weld engineer or weld mgr. position, it’s often part of the add or job description requirement that the weld engineer establish good relationships with the weld “vendors” who typically have minimal weld / application experience and rarely will have ever run a weld department.

[] Weld shops decision makers should be able to make rational weld shop decisions that are based on their process knowledge, and those decisions will have technical substance.

[] To optimize MIG – flux cored weld quality, weld decision makers need to be aware of the real world, weld process controls and best weld practices necessary for both processes.

[] To control weld costs, the weld decision makers should understand that for each common weld daily produced, their is an optimum wire diameter, that should be used with an optimum gas. With the MIG consumable there will be an optimum weld transfer mode suited to the application or specific weld. And that transfer mode will have an optimum wire feed / voltage and with automation weld travel speed. With this data it should takes less than five minutes to figure out the cost of any manual – robot MIG or FCA weld.

Note: The world’s most common MIG and flux cored weld is either a 3/16 or 1/4 (5 – 6mm) fillet weld, therefore, it’s logical to assume that with a glance at the wire feed control, each weld decision maker if asked, could within a few minutes figure out the cost of a foot, or a meter of one of these welds.

For the doubting Thomas, please note:

All It would takes is a few minutes, a weld shield and weld PROCESS CONTROL EXPERTISE to prove this:
Apart from the necessary, costly pulsed MIG equipment, and the useless three part gas mixes, many companies for the last decade have been sucked into purchasing ineffective and necessary Metal Cored and Flux Cored wires for steel and alloy steel welds which are made in the flat weld position. They will be told they are getting higher weld productivity with improved weld quality than that possible with the MIG process. These cored products will typically sell in the $2 to $6/lb range. I have evaluated and tested cored products for decades, and the weld reality is that irrespective of what the company who uses these wires has been told by their over friendly distributor or product rep, when welding on clean materials that are free of mill scale, the flat – horizontal position welds produced with the cored products, will rarely in contrast to MIG wires, (cost approx. $1/lb), offer when used correctly, any real weld quality or productivity benefits.

I believe that the continuing growth of the often not necessary costly Metal Cored & Flux Cored Wires, and also the use of the useless Three Part MIG Gas Mixes that are also utilized throughout the global weld industry, is strictly based on both weld sales influence and of course on the lack of weld shop management / engineering weld process control – best practice expertise.

For those of you that have never met me, you may have an interest in my back ground. For five decades, I optimized MIG and flux cored welds in more than 1000 plants in 13 countries. And for three decades, while working for some of the world’s largest producers of weld equipment – consumables, I was responsible for process control training and testing and evaluating global weld equipment and consumables. I helped write the AWS MIG gas specifications and advised the AWS committee on the flux cored specifications. Irrespective of the weld applications that I assisted companies with, I always achieved the highest possible weld quality – productivity, with no weld rework and no weld spatter issues. The MIG – FCA welds that I produced, were attainable with weld process expertise and the utilization of the lowest cost MIG welding equipment and MIG – FCA consumables.

Note: If a company wants to know how much weld salesmanship has had an influence at their weld shop floor, all any manager, engineer or supervisor has to do is think about all the MIG power sources and gas mixes that have likely tried in their facility during the last few years, and then take a look at MIG mixes in the cylinder storage racks. No matter what steels are MIG welded in 2015, any company that has used, or is using “three part gas mixes”, or has or is using straight CO2 or the common argon – 25% CO2 mix in their plants, is simply a company that suffers from MIG weld process expertise, a company that unfortunately has been influenced by MIG Gas Salesmanship.

FURTHER INFLUENCE OF WELD SALESMANSHIP:

In the global weld industry, it’s easy to find managers or supervisors that to resolve their daily weld issues. will seek a salesman who will pull out a glossy brochure and offer a marketing induced promise of weld improvements that rarely happens. In the case gas MIG mixes the supplier or gas mfg. wants that monthly gas / cylinder revenue and will therefore encourage the weld shop to utilize their so called unique MIG gas mix. This is one of the reasons that for four decades, we have had available in North America and Europe, as many MIG gas mixes as there are breakfast cereals available on the shelves of a super market.


The value of any weld inspector is in something most dont have, it’s called weld process control / best practice expertise. This expertise would help them prevent weld defects, rather than dimply finding them.

Please dont get pissed off at the messanger. How sad woulD a US weld shop be if it did not have persons who would vote for Donald Trump, persons without thick skin, persons without serious attitudes, persons without inflated egos, and persons with no sense of humor.

When weld shop customers do not have a clear understanding or are confused about the weld processes and the consumables that they use daily, it’s an easy task for those that produce and sell industrial MIG gas mixes, to ask for a premium price on what in reality is often a useless low cost commodity product.

ONE WAY FOR MAJOR MIG GAS PRODUCERS – SUPPLIERS TRY TO GET HIGHER PRICES FOR THEIR MIG GAS MIXES, IS PROVIDE SALES INFLUENCED BOGUS WELD CLAIMS ABOUT THEIR LATEST THREE OR FOUR PART MIG GAS MXES.

WHEN A COMPANY PROMOTES A THREE OR FOUR PART MIG GAS MIX, THEY ARE SUGGESTNG THAT THE THIRD OR FOURTH COMPONENT IN THEIR UNIQUE MIX IS GOING TO HAVE A WELD QUALITY – PRODUCTIVITY RESULT THAT WILL BE READILY MEASURABLE , & THERFORE JUSTIFY THE HIGHER GAS PURCHASE PRICE.

2015: I HAVE BEEN EVALUATING MIG GAS MIXES SINCE THE 1960s AND THE WELD REALITY IS THIS.

IN CONTRAST TO A RECOMMENDED TWO PART GAS MIX, WITH THE USE OF OPTIMUM MIG WIRE SIZE, CORRECT’ WELD PARAMETERS AND BEST WELD PRACTICES, THREE OR FOUR PART MIXES, WHEN USED FOR MIG WELDING STEELS – STAINLESS – ALLOY STEELS AND ALUMINUM, WILL PROVIDE NO MIG WELD QUALITY – PRODUCTIVITY OR SAFTEY BENEFITS.


Note: OVER 90% OF THE TWO PART MIXES THAT ARE AVAILABLE ARE SIMPLY NOT REQUIRED, AND THE POPUAR 75% ARGON – 25% CO2 MIX FOR STEELS OR THE HELIUM TRI-MIXES USED FOR STAINLESS, WOULD NEVER BE PURCHASED BY ANYONE WHO UNDERSTANDS THE REQUIREMENTS OF THE MIG PROCESS.. (see MIG gas section).

Global MIG gas misinformation and MIG gas selection confusion has been the norm for more than five decades. It’s a sad reflection of the weld industry that the majority of the MIG gas information found in too many weld shops is based on weld management, engineering, and supervision process ignorance, and of course, the gas info they do have has typically been provided by a weld gas salesman.

For any company that utilizes a three part MIG gas mix for carbon steels, alloy steels, stainless or aluminum applications, they may be embarrassed to find out they have been part of an industrial gas marketing con game. For a few years I was a primary contributor to the American Weld Society (AWS) committee that wrote the MIG Gas Specifications. Much of my time at these AWS specification meetings, went into trying to keep the extensive sales biased, incorrect. BS data that was presented on the three part mixes, out of that AWS specification. For decades it was a a sad fact, that many of those that contributed to the AWS Weld Specifications, were personnel that had a marketing or sales management or biased background.

In the last three decades, in my research roles at Airgas and AGA I developed four of the most practical, low cost, two component MIG gas mixes which are today sold throughout North America. If you want to stop wasting money on three part mixes, check out my low cost MIG gas mix recommendations. For MIG gas information without sales bias, visit the MIG Gas section at this site.


For five decades the most common sentence that I heard in weld shops was, “WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT?.

You will never hear this in your weld shop…


OVER FIVE DECADES, I HAVE ASSISTED MORE THAN 1000 MANUAFCTURING PLANTS IN 13 COUNTRIES. IN 99% OF THOSE PLANTS, I COULD NOT FIND A MANAGER, ENGINEER, SUPERVISOR, OR WELDER THAT HAD THE NECESSARY MIG & FLUX CORED WELD PROCESS CONTROLS & BEST WELD PRACTICES EXPERTISE FOR EITHER MANUAL OR ROBOT WELD PROCESS QUALITY – PRODUCTIVITY OPTIMIZATION.

THOSE IN WELD – DECISION MAKING POSITIONS, WHO HAVE AN INTEREST IN “MIG – FLUX CORED WELD PROCESS CONTROLS – BEST PRACTICE EXPERTISE”, MAY WANT TO REVIEW THE FOLLOWING WELD TESTS, AND THEN CONSIDER THE WELD COST – QUALITY – LIABILITY RELEVANCE AND IMPORTANCE OF THESE QUESTIONS FOR THEIR OWN WELD DEPARTMENTS.

Ed’s MIG Weld Process Controls Test.

Ed’s Flux Cored Process Controls Test.





A REASONABLE QUESTION ABOUT THE GLOBAL WELD INDUSTRY WOULD BE... The weld industry is an old well established industry in which the majority of daily welds are made with two weld processes, MIG and Flux Cored. These two weld processes are little changed from the processes that welders were using many decades ago. So a reasonable question would be, why would someone want a management or supervision role in an industry that is governed by processes and consumables and yet lack the process and consumable expertise for process optimization?

The wide use of MIG welding started in the 1950’s. I started MIG welding tractors at Massey Feguson around 1961 at a factory in Manachester UK where the weld shop management / supervision knew little about MIG Weld Process Controls – Best Weld Practices. I suspect if I visted John Deere tractor plants in 2016, I would find that most of the managers / supervisors still know little about MIG process controls – best weld practices. The consequence of lack of process expertise is global in scope.

After my 50 plus years of being in the welding industry, Im’n running out of time, and I wonder what it will take to get this industry to realize that there is much more to MIG and Flux Cored welds than that provided by the “welder’s skills” .

OTHER INDUSTRIES HAVE HIGHER LEARNING STANDARDS: I have never met a machine shop supervisor who would allow one of his machinists to ‘play around’ with their lathe or milling machine controls. So why would any experienced weld decision maker allow their weld shop personnel to play around with the much more simple, two control MIG / Flux Cored weld processes, the answer to this issue is a simple one.

For decades many of those involved in weld management, engineering, supervision and weld education have simply not been aware of the benefits or the requirements of MIG – Flux Cored Weld Process Controls and Best Weld Practices

Dumb ROBOTS always need optimum process data.

Robot MIG Weld Process Controls Program.

SOME MANAGERS MAY ORDER MORE ROBOTS TO ATTAIN EXRA WELD PRODUCTION, WHILE THE REALITY OFTEN IS THAT THEIR EXISTING ROBOTS WILL HAVE NEVER ATTAINED THEIR DAILY MIG WELD QUALITY – PRODUCTIVITY POTENTIAL:

THE MAJORITY OF THE MIG WELDING ROBOTS THAT HAVE BEEN PURCHASED IN THE LAST THREE DECADES, RARELY, CONSISTENTLY ATTAIN THEIR WELD QUALITY AND WELD PRODUCTIVITY POTENTIAL.

It makes little sense, why any company that takes pride in it’s level of engineering, manufacturing and weld expertise, to spend thousands and maybe millions of dollars on robots and the related weld equipment and fixtures, and then let their managers, engineers and supervisors scratch their heads when weld quality – productivity issues occur, and continue daily to put up with poor weld quality, rejects, rework and let their workers “play around” with the robot weld data.

There is a simple low cost solution to the global lack of manual – robot Weld Process Control – Best Weld Practice expertise. During the last four decades, I developed the world’s most simple, self teaching / training MIG – Flux Cored weld process control – best practice programs. The programs utilize my unique, “Weld Control Clock Method” With the weld Clock Method, participants with or without MIG expertise, will within a few hours of training be able without taking notes to attain the MIG – Flux Cored Process Control – Best Weld Practice Expertise that’s necessary to instantly set optimum manual and robot MIG / Flux Cored weld data / practice for any weld applications.

ROBOT WELD PRODUCTVITY ISSUES. ROBOT WELD QUALITY CONCERNS. ROBOT WELD REJECTS. ROBOT WELD REWORK. ROBOT WELDS AND LIABILITY CONCERNS, AND LET’S NOT FORGET THE CAUSES FOR ROBOT DOWN TIME.


To attain optimum “robot” MIG weld quality and productivity or instantly deal with robot weld issues that effect down time, requires MIG Weld Process Control expertise. With the global average robot MIG weld production efficiency range at only 40 to 60% of it’s real potential. With the too frequent questionable weld quality and costly robot weld rework usually in the range of 20 to 100%, many manufacturing companies would with the expenditure of $300 on my self teaching and training process resources have a great opportunity for dramatic robot weld cost reductions and robot weld quality improvements.

For a few years, I was the North American Robot Weld Manager for ABB Robotics, at ABB I used my process programs to establish the world’s first, “Robot MIG weld Process Control Training Program”. For the last two decades, when employed as a Weld Process Control Consultant, I provided both manual and robot weld optimization and training to numerous companies in 13 different countries.

Before I optimize a companies’s robot weld quality or productivity, I would start out by providing my Seven Steps to Robot MIG Process Controls Training Program to all the weld decision makers at the plant. I would not provide this type of training program unless all the relevant management and engineers agreed to attend the program, getting these people to attend anything to do with welding was often like pulling teeth. The reason it was important that the front office personnel attend the training, was, lack of management and engineering weld process ownership has been and still is a major part of global weld problems. The bottom line is to establish and maintain the required Best MIG – flux cored Weld Practices in any plant, requires that all weld decision makers have process expertise and walk the same welding path.

Note: I developed my MIG and Flux Cored programs so that anyone (no weld expertise required) could present them.

MIG – FLUX CORED, MANUAL OR ROBOT WELD CONTROLS. Why not provide your employees with one of my easy to use weld Process Control – Best Practice training programs. Imagine after a few hours of viewing this unique resource, that all the participants will have the ability to instantly address their daily robot or manual MIG weld issues which impact the daily weld quality and productivity. Imagine, a weld department where no one “plays around with their weld parameters” . And imagine the plant management satisfaction when the weld shop daily achieves consistent, optimum weld quality / productivity without weld rework all at the lowest possible weld costs.


A management mystery in too many global weld shops, is the real world COSTS of the common MIG or Flux Cored welds that are made daily.

.

.

MIG AND FLUX CORED WELDS AND COSTS? A weld department cannot maximize it’s profits or control it’s MIG and Flux Cored weld costs, unless someone fully understand the primary weld processes utilized. One of the world’s most common welds is a MIG or flux cored 1/4, ( 6mm) fillet weld. Do you believe anyone in your front office or on the weld shop floor has the ability to look at the weld wire size, glance at the MIG wire feed control and then instantly provide the real weld costs associated with that fillet weld. Using my process control resources, this weld cost task would be so simple that the weld decision maker would not even require a pen or calculator.

When you ask a manager the cost of a MIG or flux cored weld, the majority of managers typically will want to talk about the cost of the weld gas mixes and the cost of the weld wires.

Many weld supervisors think they are on top of the weld production as long as they see that the welder’s shield is down and weld smoke and sparks are being generated. What the supervisors and management is often not aware is, the welder working hard can weld a vertical up flux cored 1/4 fillet at 6 lb/hr, or with process control expertise set the same fillet weld with the wire feed set to deliver 10 lb/hr. Or you could have a MIG welder working up a sweat to weld a common, horizontal 1/4 (6 mm) fillet at 6 lb/hr, and with the same sweat, using my MIG process control data they can make that fillet weld at 12 to 20 lb/hr.

The weld reality is few managers or supervisors understand the weld deposition rate potential of the weld process and consumables they use for the applications they daily weld. It’s a sad reflection of the industry that i love, that you will find that less than five percent of managers and supervisors will have the MIG – Flux Cored weld process control knowledge and expertise necessary to optimize their weld quality and control and understand their real weld costs. That’s the bad news. the good news is the solution is a simple one. My unique, low cost weld process control training resources enables the attainment of consistent, optimum MIG and flux cored weld quality and productivity for the majority of weld applications, and these resources simplify weld costs.

The often touted global shortage of MIG and Flux Cored welders, has always been a weld myth:

Pick up a weld magazine in any industrialized country, and you may read about how some manufacturing executive or plant manager is concerned about the so called shortage of qualified MIG – TIG or Flux Cored weld personnel?

Company [A] is required to increase it’s weld labor force for a contract that involved MIG welds on construction, food processing and farm equipment parts.

Company [B] A job shop looking for welders to weld chemical tanks and pipe welds with the flux cored and TIG process. The welders must pass an ASME Sect 1V. 5G. welder qualification test.

Company [C]. A ship yard has a large MIG or flux cored weld project coming up, and will need to hire many more welders. In the past when the welders have taken the welder qualification test, typically one to three out of every ten welders tested will pass the tests, and extensive costs are occurred in this frustrating task. Also few of those that pass the weld test will have the process expertise that’s necessary to produce welds with minimum defects and with maximum productivity.

Most managers and especially HR department management, are typically not aware that if they simply could find people without drug problems, people with a good work attitude, and then by providing my process control training programs, and hands on training recommendations, that it would take approx. 40 – 60 hours to train a “person who has never welded” to produce code quality welds for any application and any weld position.

Those going through my process training programs would have the capability to provide optimum MIG and Flux Cored welds that would meet any global weld code / specification requirements. Of course these same companies could also have the trainee weld personnel attend the usual local weld training establishment and after six months of costly, wasted effort, you would find that the new welders have a few skills and yet they typically will still “play around” with their MIG and flux cored weld controls.

THE TRADITIONAL TIG PROCESS REQUIRES THE HIGHEST WELDER SKILLS WITH MINIMAL PROCESS EXPERTISE. FOR SOME IT TAKES MANY YEARS TO MASTER THE SKILLS REQUIRED FOR CODE, ALL POSITION, PIPE WELDS. HOWEVER SINCE THE YEAR 2000, THERE HAS BEEN A SIMPLE SOLUTION TO THE GLOBAL TIG WELDER SKILLS SHORTAGE. THE SOLUTION IS CALLED TIP TIG.

WITH THE TIP TIG A PROCESS THAT I INTRODUCED IN BOTH NORTH AMERICA AND AUSTRALIA, YOU COULD TAKE SOMEONE WHO HAS NEVER TIG WELDED OR WELDED PIPE, AND WITH THE TIP TIG PROCESS IN APPROX. 10 DAYS, THAT PERSON SHOULD BE ABLE TO MEET ANY ALL POSITION, CODE, PIPE WELD TEST.

By the way, the TiP TiG manual or automated pipe welds will be better quality than any regular manual TIG welds, and better quality than any Hot / Cold Wire automated TIG welds. As a bonus the TIP TIG welds will be done 200 to 400% faster always with superior metallurgical properties. www.tiptigusa.com. Ask for Nick and tell him Ed Craig sent you..

If you want to increase the rate at which new hire weld personnel can pass any MIG – Flux Cored weld qualification test, it would make sense if the weld decision maker in charge would insist that before the welders waste the weld costs associated with weld testing and weld coupon evaluation, they sit those involved with the test down in a classroom and give them a few hours of my weld process controls, and best weld practice requirements .

It’s a good job for most weld shop managers, supervisors and engineers that
NDT or Macros are rarely used on their MIG – Flux Cored welds.

AS YOU EXAMINE THIS PHOTO, IS YOU HAD PURCHASED MY FLUX CORED PROCESS CONTROL PROGRAM YOU WOULD INSTANTLY KNOW WHAT THE ROOT CAUSE WAS.

If NDT was applied to all global MIG and Flux Cored welds, approx. 70 – 80 % of the welds would have defects that are not considered acceptable to any weld code requirements. Its logical and highly beneficial that all weld decision makers learn with process control training, how to instantly diagnose MIG – FCA weld defects, and be aware of how to prevent them from occurring.

I suppose most weld shop managers and supervisors are relieved that the majority of their r welds will not require “internal weld evaluation” However from a safety and product liability perspective, however as no additional weld costs are required, you would think weld shops would want to always ensure the highest possible manual or robot weld quality.

In contrast to most welds, common codes such as API, ASME, AWS, require weld qualification procedures, yet every code weld that has failed or has serious defects, will be a weld that was supposed to be made with so called, pre-qualified weld procedures and qualified skilled welders.

WITH MOST CODE WELD DEFECTS, THE MANAGEMENT FOCUS IS OFTEN ON THE WELDER WHO MADE THE WELDS, WHEN IT’S A GOOD POSSIBILITY, THAT THE WELD PROCEDURE, THE PROCESS, THE PARAMETERS OR CONSUMABLES UTILIZED HAD A LARGE INFLUENCE ON THOSE DEFECTS.

Apart from the welder’s skills, an essential element to the success of any weld project, is the implementation of Best Weld Practices, and assurance that the weld personnel doing the weld decision makers providing the weld qualification procedures, have the necessary Weld Process Control Expertise.

Response to variables is an important welder’s function

I always find it interesting in the weld shops I visited, to watch the weld personnel respond or not respond to the numerous variables that are affecting their welds.

Apart from the welders “playing around” with their MIG or Flux Cored weld controls, how would the weld personnel in your shop, respond to the following?;

[] welds with too small or excess root gaps,
[] welds with joint misalignment,
[] welds with poor weld edge preparation,
[] welds with poor weld joint access,
[] difficult out of position welds,
[] welds on unacceptable surface conditions,
[] welds with undercut,
[] welds with crater problems,
[] welds that are causing distortion,
[] welds that are creating cracks, lack of fusion, porosity or spatter,
[] and lets not forget, the influence of welds that are made in changing environmental conditions.

A WELD REALITY: Few weld shops have ever provided their weld personnel with the process control – best practice training necessary to correctly respond to the variables that daily effect the weld quality or productivity.

Imagine the weld cost benefits of a weld work force that is trained to understand how to react to weld variables. Imagine using welders that know how to minimize the formation of weld defects, and will always use weld settings that ensure maximum hourly weld productivity.

If you are a weld shop decision maker and you want to create cost affective changes in the weld shop, you have these two simple options;

[1] Get advice from another weld salesman.

[2] Or use the unique manual / robot MIG and flux cored weld process control trainingresources. available at this site.

My simple Weld Clock Method, simplifies MIG & Flux Cored weld parameter settings.

Set that MIG pipe root weld, or a common 16 gauge MIG weld. Wire feed. 11 o’clock, with 17 cups of coffee, (17V).

Click here to add your own text

The following is in the home page Section 2.

[] Find out why the inspection approach of most QA weld managers is simply not cost effective.

[] View the best inconel, stainless, pulsed MIG “clad” welds that have ever been made in North America.

[] Find out why so many companies that do code quality welds are stuck in a 1960s weld time warp.

[] Find out why companies should not be using self shielded flux cored wires, when they want to attain quality welds and good mechanicals.

[] When the weld equipment and processes are not optimized you would think someone in management wants to generate change.

[] If you have any sense you don’t make MIG welds like most Japanese manufacturing companies.

[] Find out why the “robot weld team” is frequently a good resource for the management to water down and spread out what should be their role and responsibility.

[] This North American car parts plant was unusual. I found two managers that showed an interested in the requirements necessary for optimum robot weld quality – productivity.

[] Find out why the Chrysler corporate management lost over 20 million dollars from bad welds on one easy to weld part.

[] Why the big three wastes millions of dollars each year for welder training.

Continue Home Page. Section. 2.

Or perhaps you are interested in seeing how easy it is to save millions of dollars with large weld fabrication projects take a look at the following;

HOW THIS SHIP YARD SAVED MILLIONS FROM WELD QUALITY – PRODUCTIVITY IMPROVEMENTS:

HOW THIS OIL COMPANY SAVED MILLIONS EACH YEAR FROM INCREASED PIPE WELD PRODUCTIVITY. Click here.

Low wages yet management pays ridiculous
prices for useless MIG equipment.

Asian management loves to waste money on useless
MIG weld equipment electronic bells & whistles.
Visit Ed’s Process Training Resources.

Please don’t leave this site without checking Ed’s MIG- Flux Cored best weld practices and weld process controls resources.

Whats in Home Page Section TWO.

Why Dow Chemical often looks like it’s stuck in a 1960s weld time warp.

Magna uses Ed’s Robot Process Control Training program.

What do ship yards and auto plants have in common?

Why the common QA weld inspection practice often fail.

When the robot welds are difficult this USA Big Three company ships the parts to Mexico.

FEMA the weld joke.

Would this be Einsteins Theory on MIG welding?

One prime reason the North Ridge welds failed during the earth quake.

More Motoman weld issues.

Another reason many robot weld managers have raised the white flag.

Why the Volvo manger was wrong to want to hire skilled welders to run his robots. (page 3)