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

Weld Process 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, the weld process controls, and best weld practice requirements. The site also provides the self teaching and training resources that are necessary for any weld department to consistently attain the highest possible, manual and robot arc 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 Expertise.

The importance of Weld Process Controls, Best Practices.
MIG, Flux Cored, TIG &  the TIP TIG process.

Welding
Consistent manual or robot arc weld optimization is not possible without weld process controls & best weld practice expertise. This expertise is not provided in most global companies that weld, or in the educational engineering facilities and trade schools that provide weld programs.

For four plus decades, the majority of companies that utilize arc welding processes have typically seen minimal weld quality – productivity improvements. The slow arc weld process control evolution for the weld industry has been related to the lack of management, engineering and supervision weld process controls and best weld expertise, and this lack of expertise has influenced the common global  “play around” with the manual  – robot weld settings shop practices. This lack of expertise also accounts for the prolific lack of management, engineer and supervision Weld Process Ownership and Weld Quality – Productivity Ocountability.

From ship yards to automotive plants, from the oil industry weld shops to aerospace weld departments, it would take an experienced weld process engineer ten minutes to find either manual or robot weld process confusion, unnecessary poor weld quality, rework and rejects, lack of weld uniformity, and often poor weld productivity. Add to this, the  general lack of front office understanding of weld costs and you can understand the why change, slow weld evolution with simple processes that have changed little in decades,

THE GLOBAL PROCESS CONTROLS SOLUTION IS EASY TO REMEDY BUT IT TAKES A MGR. TO OWN & DRIVE CHANGE IN A WELD SHOP.

The resolutions for the lack of MIG – Flux Cored – TIG process controls – best practice expertise are both simple and low costs. I have simplified  the training or self teaching programs and made them available at this site. However for weld departments to reach their manual or robot weld quality – production potential with the arc processes mentioned requires that all walk the same quality – production path and that the changes be generated, owned and driven from those in the  weld shop front office.

Lack of Welding Process Control Expertise and Ownership will;

  • influence management, engineer and supervision reliance on sales advice to resolve many of their weld shop issues,
  • influence the weld personnel  “playing around” with the weld controls,
  • influence the “why change” stuck in the past, common weld shop culture,
  • influence the lack of ability to consistently attain the full manual or robot weld quality & productivity potential from one or two control, well established arc weld processes,
  • influence the lack of uniform &  practical, cost effective weld equipment & consumables, this should be evident in all weld shops,
  • influence the ability to recognize superior cost effective ways to weld, this opens the door for extensive weld cost reduction potential,
  • influence a lack of in-depth understanding of weld costs. Usually a manger is more concerned about the price of a weld wire than the weld deposition rates and quality attained.

    Consequences of lack of adequate weld evolution: 
    There are many companies that have decades of weld process and weld application experience, however there are few global weld departments and weld shops that will consistently;
  • Ensure the highest possible weld quality.
  • Ensure the best possible after weld part metallurgy.
  • Ensure the highest possible weld productivity.
  • Ensure the lowest possible weld cost are attained.
  • Ensure the lowest possible part distortion.
  • Ensure the lowest weld cleaning is required,
  • Ensure the least possible grinding and weld fumes are attained.
.

Missing link. Management & supervision lack of weld process ownership.


This manager could also ask. “In a court of law, do you think it will
be the welders that are held responsible for the screwed up welds”?

WIDGETS OR WELDS, MANAGEMENT HAS A ROLE.  If welding is not your thing, please give some thought to this… Envision a mfg. facility that makes widgets. The prime mfg. process used in the assembly are dumb, simple machines that we will call Trump Boxes, (TB). The TB boxes have  changed little since they were introduced five decades ago. The TB machines operate with two simple controls, and usually only require three settings to attain optimum widget results. The TB settings can be low – medium – high, and the selected settings will effect the low – medium –  high speed of  the related equipment. The sad reality is there is not one manager, engineer, supervisor or technician in this plant that has figured out how to optimize or take ownership of the TB equipment. The management solution is to order more Trump Boxes and increase the budget for the ever expanding QA department. In this department the inspectors are trained to find the defects that result from the poor TB settings. Unfortunately these inspectors also don’t know how to optimize the TB controls.  Arc weld equipment and the TB boxes have much in common  and the above could be a description of how the majority of global weld shops and weld departments have been run for decades. I hope if are involved with welding decisions that you will see how ludicrous this situation is .

From the manual arc welds found in the weld shops of the Aerospace, Defense, Medical, Power, Oil  industry, and others, to the robot arc welds produced on your favorite car or truck, please take a moment at this site to consider where as an industry you are in 2018, and also what is required to make the changes that can improve your daily arc weld quality or  productivity.

For too many global weld shops, the daily weld norm may be;

  • dealing with inconsistent weld & part quality,
  • never attaining the weld production potential from the processes and consumables utilized,
  • a lack of awareness of the real weld  costs,
  • unnecessary weld defects, rejects, rework, weld cleaning and grinding,
  • the common lack of practical weld equipment & weld consumable uniformity in the weld shop,
  • the lack of front office ability to purchase practical, cost effective weld equipment without the common unnecessary costly, (bells whistles), often recommended by a sales person,
  • purchasing unnecessary three part MIG gas mixes to Metal Cored weld wires, the inability of the weld decision makers to again recognize what’s real and whats  sales BS.
  • Stir in the general lack of weld shop best practices and process control expertise. Then add to this pot reference weld expertise, the weld shop’s inability to cut the umbilical cord to their weld suppliers, with  the liability cost consequences of failed welds. and the encroaching, lower weld labor costs from competitors in the global weld competition, and  what does it all add up to?

From Defense to Auto Plants, from Ship Yards to Aerospace, In all industries in which welding is an important function, the most difficult thing to find is a manager or supervisor who has the required process control expertise necessary for weld process ownership.

More evidence about WELD OWNERSHIP &  ACCOUNTABILITY:  Over five decades, in providing weld process quality and productivity improvements,  I visited over a 1000  companies, in 13 countries.  On these visits from Aerospace plants to Automotive plants, I saw no evidence of front office required weld process control – best practice expertise for process ownership necessary for the plants to attain their daily weld quality – production potential.

In 2018, you will find that the majority of global shops that produce “arc” welds are producing welding quality and productivity that is hardly  better than most of the arc welds that were produced in the weld shops that  I worked in 1962.

The relationship of the weld process selected & weld defects,

Weld defects often result from the process, consumables, the metals welded, and poor procedure data, and are often NOT the fault of the welder.


Common weld defects such as lack of fusion, porosity, undercut & slag could be added to those defects above. All of which can result solely from the weld process & weld consumables selected.

I suspect that when it comes to weld defects, many in the weld shop front offices will point to their welders as the prime cause of their manual or robot weld issues. Apart from the fact that most managers and supervisors neglect (most not aware) to provide their welders  with process control – best weld practice training, 

There were FOUR Prime Arc welding processes. For decades, and in 2018, the majority of global weld shops, when “all position”  arc welds are required on  steels and alloy steels, will typically consider four common arc weld processes.  SMAW,  Pulsed MIG, Flux Cored and TIG. These four important  processes when used for steels and alloy steel applications, have seen few equipment / process changes that have in reality advanced weld quality – productivity. This includes Pulsed MIG welds. Most of the pulsed MIG steel  and alloy steel welds made in at present could be produced just as effectively using much lower cost CV. MIG equipment,  and the short circuit and spray transfer modes and weld process expertise.

The SMAW Arc welding process: For fifty years I have avoided the use of this inferior arc process, and would not consider SMAW as a logical choice for code quality weld applications.  The logical choices would be flux cored or TIG. Their is always an exception for example ignorance, weld  access, reach or an environment concerns.

The Flux Cored Arc welding process: With gas shielded flux cored welds, any experienced weld decision maker would be aware that even with optimum skills and parameters utilized, there will be no guarantee with NDT, that the flux cored welds wont have serious common FCAW defects such as trapped slag, worm tracks or porosity.

The Pulsed MIG Arc welding process:
  When a high deposition process such as Pulsed MIG uses a back ground current, the pulsed weld energy in contrast to the spray mode is reduced. Using manual Pulsed MIG welds on steels and especially  sluggish > 5/16 alloys such as stainless, it would be difficult to ensure that the MIG welds have consistent acceptable weld fusion.

The TIG Arc welding process:
Regular TIG  is the arc process with the most high weld quality expectations, and has been a prime choice for code quality and alloy welds.  TIG also produces very low deposition rates (slow travel high heat) and requires the highest welder skills.

TIG skills differ from welder to welder and this influences the weld quality and uniformity attained.  Most TIG welds require that the manual welder dip and withdraw their TIG wire length into the TIG arc plasma and weld pool. This unique arc weld practice again varies from welder to welder and again a practice that influences the weld quality uniformity and consistency attained. Also with many TIG applications and the very slow weld travel rates that often result, with TIG the weld shops see small defects influenced mostly by skills and practices and the shop may have concerns for high weld and part heat, something that few alloys will benefit from.

Since 2010, TIP TIG  is  Arc Welding Process #5.  In the last decade, we have seen dramatic TIG power source changes  for the important  AC. TIG process used for aluminum.  However in the last decade, the most important arc process change is the Semi-automatic and the Automated TIP TIG process.  Read the numerous TIP TIG weld quality – productivity benefits below.

Single manual pass, untouched, TIP TIG, 5/16 stl. fillet made by Ed 2011. Do your welds look like this? Note unique, weld cleanliness, continuity and the minimal weld HAZ .

In an industry slow to evolve, the process evolution fundamentals: To change from arc weld processes that have been established over many decades, first requires that  front office weld decision makers understand the weld benefits and limitations of the processes they utilize (rare event) before they can compare the quality – productivity results of  the new process or consumables under evaluation.

In the their decision for well process change, a good weld manager would be aware of  process feature benefits, and just as important, the process limitations. The weld decision maker would also have the weld process – best practice expertise that’s necessary to take the new process to its full weld quality – productivity potential.

For those that visit this site and want to attain the best possible weld quality, please be aware that I have written the data on this site since 1998.  Also over a five decade period, I have been resolving weld issues in over a 1000 plants in 13 countries. So please while at this site, don’t expect the usual sales induced BS about weld processes, or expect that the solution to your weld shop issues will come from another three part magic gas mix or a unique MIG power source that as its been for 30 years will be loaded with more costly, useless electronic bells and whistles.

WELD CREDIBILITY & EXPERIENCE:  As we all are aware, the weld credibility and application experience of the the person providing weld advice has to be  relevant. In this section, I provide a few of my weld application experiences over a five decade period. I also provide the weld resolutions to many global weld shop issues, along with my Arc Weld Process Controls – Best Weld Practice Training – and Self Teaching programs. The primary weld message at this site is this:

“The root cause of most of the  global manual and robot daily weld shop issues lies with the front office and supervisor’s lack of weld process control – best weld practice expertise”. The result in most global plants is that  few managers engineers and supervisors will have the ability or willingness to take ownership of the important weld processes in their welding facilities.

In 2017, From Spy planes to Spacecraft, many defense & aerospace industry “arc” welds are daily made with inferior TIG and MIG processes, outdated specifications, &  lack of weld  process controls & best practice expertise.

21st Century plane made in an industry that is still using 20th Century weld processes. specifications & procedures.


Inadequate and outdated welding specs & procedures are the norm in the 2017 global Aerospace – Defense – Power – Oil, and other high tech industries. You will find that the majority of managers, supervisors or engineers responsible,  have allowed their weld technology, specifications and often poor procedures to be stuck in the  1960s to 1980s time warp.

In high tech industries you would in 2017 expect to find the highest engineering and manufacturing standards. You would also expect high tech companies to use a modern day weld process control – best practice approach, using  updated weld specifications and  procedures. The reality too often in the global high tech industries is at that at the majority of their weld manufacturing facilities:

  • The use of outdated weld processes, specifications & procedures.
  • A lack of ability to train and implement best weld practices.
  • A lack of shop floor and front office manual and robot weld process control expertise.
  • Experienced weld personnel playing around with weld controls.
  • Lack of leadership from management. engineers and supervisors on the subjects of weld quality, production potential and the weld costs.

CODE  QUALITY ALLOYS & STEEL WELDS: 

I am well aware that daily in the Aerospace, Defense – Oil – Power – Medical – Automotive and Construction equipment manufacturing weld departments, that daily NDT is utilized to hopefully minimize the opportunity for weld defects. However as we are all aware code quality weld failures are common across all industries that utilize welds. This site has an extensive section of Bad Welds in all industries.

FEW QA DEPARTMENTS ARE COST EFFECTIVE.

While many personnel in the QA department or the front office, will put the blame for manual or robot weld issues on the weld shop floor personnel, anyone who welds knows that weld quality responsibility has to commence with the weld decisions made in both the front office and with the QA manger. Lets face it. in an industry that waste millions of dollars every day with QA personnel and practices that are developed to REVEAL weld defects after weld completion, maybe their are some logical mangers out their that would see the sense in providing their weld decision makers and weld  inspection personnel with either the manual or robot weld process control – best practice training available here, so they would have the for the first time that remarkable unique cost effective ability to help prevent weld defects.

Common occurrence, Code Quality Arc Weld Failures:  Each day in the weld industry, some code quality welds will fail with dramatic consequences to both life and costs. These welds would have initially been made in compliance with applicable Weld Specifications, with the guidance of Approved Weld Procedures, made by manual welders that were subject to Welder Qualification Tests,  and tested by weld inspection personnel who typically have minimal WELD process control expertise.

A  visit to the Bad Weld Sections at this site provides data on some of the NDT approved code quality welds that failed in Nuclear Plants, Oil Pipe Lines Nuclear Submarines, Aircraft Carriers  and Space Rockets. The bottom line is under the ineffective weld practices we use around the globe, code quality welds subject to the most rigid NDT evaluations will continue to fail, and the repercussions from the failures as its been for decades can  be loss of life and , millions of dollars paid for repairs and legal consequences.

MIG – FCAW – TIG weld process confusion and process control – best practice ignorance is in abundance throughout the global Oil industry.

If in 2017, manual Pulsed MIG, flux cored, regular TIG, or automated Hot or Cold Wire TIG processes are being used for code quality welds, especially  on welds in the high tech industries, then those weld decision makers responsible for the welds, need to be aware that they are in many instances allowing inferior weld processes to be used, as they are not using the TIP TIG process.

TIP TIG is the evolution of TIG. It’s a process that in contrast to all arc processes will provide superior weld quality. TIP TIG also enables the lowest possible distortion,  the best possible metallurgy results, the lowest possible weld fumes, and something you think that should motivate most mangers, apart from a dramatic reduction in the usual weld repair costs, TIP TIG will also reduce regular  TIG labor costs by 100 to 400%.


2017.  AEROSPACE – DEFENSE – MEDICAL  – OIL INDUSTRIES.
Weld management apathy & stuck in a 1960s  weld time warp.

Its sad that 20th Century weld technology & specs and procedures are rarely in use in the 21st Century Space Program.

Two important issues for companies such as NASA -SpaceX and Boeing with their plans for space exploration, are Costs and Quality. Yet in the case of welding, this important industry does mot lead and seems to ignore present day arc weld technology such as TIP TIG,  a simple to use process that in contrast to TIG and Hot Wire TIG, dramatically improves both weld & part quality, and reduces weld costs in the range of 100 – 400%.

An ironic 2017 Aerospace engineering fact. In their 21st Century attempt for space exploration, companies such as NASA, SpaceX, Boeing and their prime suppliers, have since 2010 have been using for most of their “arc” welds, 1970s to 1980s the regular manual TIG and they may also be utilizing the poorly suited pulsed MIG  technology.  (EB – Laser excluded). To go with their use of  these inferior processes, this industry in 2017 will most often with TIG  welds be using  weld specifications & procedures that have changed little since the NASA 1977 Voyager program.

2017: Aerospace is the one industry that has the caliber of managers and engineers that if they had an interest, could drag their stuck in the past weld industry into the the higher quality, lower cost weld potential attained in 21st Century.

A couple of my welds will go where no man has ever gone.

Thanks to rare  United Technology engineering management, I was privileged and proud for a short time to work on the Space station and Orion Spacecraft. One day maybe in the 1930s, when I am six feet under, Orion will be off on it’s long journey to Mars. My  time at United was very short (health concerns) however it was an extraordinary experience to be able work along side some of the world’s most creative engineering minds.

Apart from the traditional TIG and EB applications that I worked with at United, one opportunity I had  was to be able review  the present day (2017) arc weld specifications and procedures which are commonly in use throughout the Aerospace industry.  From my personnel perspective on the one hand it was  amazing to be part of a high tech, engineering environment, and in the other hand,  find that with the majority of the “arc” welds being made over the last decade or two,  were made on the recommendations from NASA / Boeing Weld Specifications and  there influenced supplier Weld Procedures, and these have changed little since the 1980s.

Weld technology has been be slow to evolve, however the technology and process control expertise has evolved, otherwise like Rip Van Winkle, I  have been asleep for the last 50 years. 

2017: After fifty years of optimizing arc welds, writing thee books on the necessity of weld process controls – best weld practices,  and also responsible for bringing and introducing the USA to the most effective arc weld technology ever produced, you could assume that since the 1960s, I have not been asleep on a couch with a TV remote control in my hand.

Over the decades I screwed up many things in my life,  but on the subject of welds, I evolved every day.  What I know in 2017 about the weld process technology, weld process controls & best weld practice requirements that are necessary for an organization to  consistently attain, optimum weld quality, and what I knew in the 1960’s to 1980’s time frame, would be like discussing  the differences between chalk and cheese.

When NASA, or SpaceX  or other countries spacecraft head out into space on their future long dangerous trips, engineers in 2017 may want to consider why the 75  TIG process was used for many of the arc welds, with TIG weld specification  and procedures that were influenced when the Beetles and Elvis were number one. Yes many welds are made with EB and they are fine.

The bottom line the Aerospace and Defense industries should be leading not lagging in weld technology. However in these industries when code quality arc welds are required they will come from manual TIG and most automated welded parts will be made with either  traditional TIG or Hot Wire TIG.

Yes I am aware that most of the weld specs and procedures used in both the Aerospace and  Defense industry will will have seen some TIG Weld Specification and Weld Procedure revisions over the last four decades, however  I believe that many of those revisions will usually have more to do with grammar changes and inspection criteria, than information that enables improved weld and part quality.

The weld reality for Aerospace – Defense plants in 2017,  is if the regular TIG process or the Pulsed MIG process is being utilized, the weld / part quality and weld productivity potential that could be produced is not being produced.

Another apathy and irony on the subject of weld process ownership. Most of the arc weld quality control in the Aerospace and Defense industries will in 2017 not be left to engineers or  managers, but  left in the hands of self taught Fred and Joe in their weld booths.

It’s sad when the managers & engineers & supervisors  in high tech companies leave weld & part optimization, costs, controls  & evolution, to those on the weld shop floors.

The Aerospace industry is one industry that should embrace and also encourage positive arc weld process, procedures & specification changes,

Don’t tell me with these welds, that they used regular TIG and those bloody, outdated, 1980 weld specs and procedures. 


WELD QUALITY LEFT UP TO WELDERS? LAWYERS LOVE THIS.
How often will critical Aerospace & Defense and Oil industry weld quality be left up to Fred or Joe or on the weld shop floor?  Perhaps those that are supposed to be responsible in a high tech industry such as the Aerospace, will in 2018 get some balls and “Boldly Go Where Few Managers & Engineer Have Gone Before.”   Perhaps then key weld decision makers could spend less hours on the never ending weld meetings that just go around in circles, or on the shop floor forever fighting the never ending weld shop fires.

All code weld shops should have an interest in the TIP TIG  process,  and an interest in the requirements of weld Process Controls and Best Weld Practices. Any weld decision maker can with a few hours with my self teaching – training process control resources, have the requirements necessary for arc process optimization. And surprise, they would then have the capability to take responsibility for their manual or robot weld process ownership. Maybe also then in 2018, they could bring their companies 20th Century weld methods to the weld potential capability of processes and process control expertise thats now available.

If you are a weld decision maker especially in an industry where quality has a meaning, consider “taking one small step for process ownership for the front office personnel, and watch how this can create one giant step for the companies weld quality and productivity”.  After all, who wants to  be that company manager or engineer that’s held responsible when an important  weld fails on a spacecraft  heading out to Mars? Click here for Eds now  Em  Weld Process Controls Training materials


Common costly weld results from lack of experienced
weld management in the DEFENSE industry

The norm in ship yards. Inexperienced weld process management and supervision, always poor weld quality, excess weld rework, poor weld production & always excess over budget weld costs.

From building Submarines to Aircraft Carriers, in  2017 as it’s been for decades, extraordinary excessive MIG – Flux Cored and TIG weld costs, from weld rework, rejects and poor weld production. Fortune 500 companies don’t like to hear this but the millions of dollars wasted daily are not the fault of those on the weld shop floors. The weld issues are derived mostly from the lack of weld process expertise from those that sit in the front offices and are responsible for welds.

For more than three decades, Navy engineering decision makers along with their prime contractor ship yard managers & engineers and QA personnel  have been responsible for the too common, excessive, never ending, poor arc weld quality, the over the top weld rework costs.m with of course, always  pathetic low weld productivity.

In the last decade, weld technology has advanced rapidly, with
defense weld applications time  has stood still.

In general most of the head stuck in the sand, key weld decision in the Defense, Aerospace, Oil and Power industries have simply lacked the ability to take process ownership, put process controls and best weld practices. Most. (not all)  of these personnel are nervous around weld equipment and lack the ability to recognize and approve new weld technology that has the ability to provide both quality and productivity improvements.
From poor process management to not using evolved technology, now that I’ve pissed off a lot of executives and managers in this industry, I will simply say, this, that anything I say on this web site would take me about 2 hrs prove.
Of course managers with egos will ignore what there real weld potential would be if they woke up, however being a pragmatist,  I expect little response, and after doing this for five decades the clock keeps ticking, Why Change”  and after all its only tax payers that pay most of the bills.

THE SOLUTION TO ALL ALLOY STL AND CARBON STLS CODE WELDS. In 2017,  there is a key process solution for many arc weld issues. That process is TIP TIG. This process provides higher weld quality and is easier to use than regular TIG, Hot Wire TIG and Pulsed MIG. TIP TIG also enables lower weld heat than any other arc process. This simple easy to use, highest weld quality capability and lowest weld heat combination, enables with any metals the best possible consistent weld quality and best possible weld and part metallurgical properties.

Aerospace – Defense – Oil – Medical – Power. You  would assume it’s logical to use the best  possible weld process, and consider that  weld process control and best practice expertise are relevant the responsible managers, engineers and supervisors.

Many managers make process decisions without process expertise.


Process Controls and Arc Weld Processes.
Both the MIG and gas shielded flux cored weld processes have for decades accounted for approx. 80 to 85% of welds produced daily. The regular TIG and SMAW (stick) processes account for the weld balance. Part of the requirements of weld process control expertise is to understand the inherent, unique process & consumable issues that comes with  each of the weld processes. Also be aware of their optimum weld parameter ranges, fine tune adjustments  and their  compatibility with the intended applications. Then you apply the best weld practices.

As most readers will be aware, when new weld technology comes along, its logical that  the weld decision maker who purchases the new process,  will first require weld process control – best practice expertise with their existing processes. Once a weld decision maker is aware of how to consistently attain the maximum weld quality – productivity potential from their own processes, then they a real  measure of what the new process presented has to be able to attain and what real world weld benefits will be provided. Process control expertise is not part of a job description for a welder, it’s something a manager, engineer, supervisor or weld tech can easily learn. Therefore those responsible for the welds require this this expertise, they should  own their processes,  and be the driving force that’s necessary to implement process change.

Your company welds code quality steels and alloy steels,
are they aware that TIG has evolved? Are you?

Regular TIG, inferior weld – part quality, greater distortion, higher skills and foot control, and always much higher labor costs than TIP TIG.

As every weld shop is aware, the regular TIG process produces very low weld deposition rates, typically less  than 1.5 lbs /hr, and as a result create very slow weld travel rates,  1 to 6 inch/min is the norm. The slow travel rates can depending on the part thickness result in high weld & part heat, This heat can effect distortion, oxidation and the weld & part metallurgical properties.

Any manager in 2017, who would choose regular TIG for the following stainless manifold code quality welds, should be managing a donut shop.

Next: Oil Industry. Complex stainless manifold. Weld distortion and weld quality are  logical concerns.

In 2015, what would you select to weld this stainless manifold? If you selected regular TIG, this would have been a poor choice.


When the above stainless manifold welds were changed from regular TIG,  to the TIP TIG process, the following occurred.

  • TIP TIG reduced the manifold weld costs by approx 75%.
  • TIP TIG dramatically reduced distortion.
  • TIP TIG reduced welder skills, improves weld quality capability.
  • TIP TIG enables maximum control of the filler wire placement continuously into the arc’s  plasma sweet spot.
  • TIP TIG enabled smaller diameter weld wire to be used with higher weld amps providing increased weld wetting, better fusion.
  • TIP TIG adds Hot Wire amps to the weld wire adding to weld energy.
  • TIP TIG agitates the weld puddle, which with the increased weld energy slows the weld solidification. Higher weld pool energy in an agitated weld pool provides for superior side wall fusion and welds with less porosity potential.

For those interested in the TIP TIG process and the opportunities this process can bring to your weld shop and future weld applications you may be interested in bidding on, please note the following facts;

  • TIP TIG is easy to learn. It take a day or two to learn and the supplier provides the training.
  • TIP TIG can be used from the pipe root to the all position pipe fill passes.
  • TIP TIG with increased TIG deposition rates is cost effective even on thick materials.
  • TIP TIG requires only three weld settings for all welds.
  • TIP TIG attains the lowest possible weld heat input derived from higher TIG weld speeds and DCEN heat distribution into the parts.

Please NOTE: Every alloy takes its metallurgical benefits from heat treatment. TIP TIG and its lowest weld heat provides the smallest possible weld HAZ. Even alloys like Titanium can be welded without a trailing shield. This process changes or eliminates the pre-heat, interpass or post-heat rules that for decades have been applied to all alloy welds.

  • TIP TIG will readily reduce TIG weld costs from 100 to 400%.
  • TIP TIG with less arc length sensitivity than TIG is readily automated. A great process on a low cost  Bug-O or on a robot.
  • TIP TIG with no spatter, minimal repairs and no gas mixes, should be one of the lowest costs weld processes utilized in a weld shop.
  • TIP TIG with no spatter and the lowest weld oxidation potential enables the lowest weld cleaning costs.
  • TIP TIG provides less weld fumes than any other arc process.

Note: In North America, around the year 2010, I went to Scotland to evaluate TIP TIG. After my return to the USA with the funding from my business partner Tom O’Malley we  introduced TIP TIG to both N America and Australia. The company is TIP TIG USA and at that moment in 2010, the traditional TIG process,  the automated HOT & Cold Wire TIG process and pulsed MIG process became obsolete.

TIP TIG was invented and patented in Austria by S. Plasch who was assisted by his son U Plasch.

SubSea valves clad welds using outdated Hot Wire
TIG,  producing inferior weld quality & production.

The TiP TiG arc welding process

Using TIG or Hot Wire TIG, you are behind the times.


Few mfg. plants like CHANGE
.  Year in, year out, most  welders will sit on the  same seats in their lunch rooms. Frankly most people don’t like change.  In weld shops surely it’s the role of the front office decision makers  to drive change that can improve weld quality and help the companies  bottom line.

To recognize the benefits of new weld technology, those front office plant personnel would first have to own and recognize both the positive and negative attributes of the primary processes they daily utilize. This expertise in the global weld industry is as rare as a Rembrandt painting.


For four decades, the the Dow Chemical
approach to many of their weld applications.

Why change? With stick welds, who needs process expertise? its just amps up or amps down.


DOW CHEMICAL, A SAD WELD DINOSAUR:
  
I had just visited a mid-west processing plant in which Dow, one of the USA largest chemical companies had requested that their 3 inch (75mm) thick, 304 stainless vessel, that was approx. 8 feet (>2 m) in diameter, was to be welded only  using 1/8 (3mm) diameter SMAW electrodes.

Over the years, with some of projects I worked on, I had seen the love affair from Dow engineers for the most simple and oldest arc weld process, SMAW (stick). Big or small jobs, SMAW was the common process choice,  and it’s a choice that was often influenced by previous old applications that were often designed from 1950s to 1980s. The DOW engineers must have lacked confidence in their weld process expertise, and therefore having small balls they would utilize the weld process that was used on similar applications often before they were born. It’s sad that an engineering giant like DOW gave little thought to the present day weld process choices that they and their fabricator suppliers could have used on many of their world wide construction projects. In many instances the utilization of  MIG – Flux Cored or TIP TIG, would have been the logical weld selection decision, and the weld quality and productivity improvements would have created hundreds of millions of dollars in savings. However the Rip Van engineers at DOW seem to be content to maintain the status quo of  “this is the way we have always done it”.

So in 2017 for those weld industries or weld shops that still utilize or consider  SMAW,  TIG or even pulsed MIG for alloys, and all metals that require all position code quality welds, the bottom line is  they are not only using out-dated weld process technology that is likely impacting their weld quality and costs, they will also likely be using out-dated weld specifications and weld procedures.

Someone should write a song for the weld
industry and call it, WHY CHANGE?

 The weld industry Swan song. “WHY CHANGE”.

TIG was invented by Northrop Aircraft in 1941. Seventy eight years later and  thanks mostly to management and engineering lack of process expertise and process ownership, TIG is still the  primary arc weld process used at Northrop.

Question: Ed, I thought that part of the job descriptions of most engineers and managers would be to be responsible to embrace and drive new cost effective weld technology changes.

Answer: Well first Ed is now Em. The facts in 2017,  are arc weld process controls and best arc weld practices are still not taught in most of the global universities and colleges that educate welding and mechanical engineers. So therefore its logical that this expertise is a missing link in industry and so the safest thing that the majority of managers / engineers will do in this  weld environment, is do NOTHING.

Lets face it, Its much safer to simply maintain the “this is the way we have always done it”  culture and status quo then drive  process changes that will require justification, new procedures and training,  functions  by the that should be a normal function of any manufacturing manager, engineer and supervisor.

My unique robot weld process control self teach and train program will only benefit those that have an interest and can read.


WHAT ABOUT ROBOT WELDS?
  With most robot MIG weld cells, and the largest user of robot MIG weld cells is the global auto and truck industry. In this industry, poor and inconsistent robot MIG and resistance weld quality and productivity is the daily norm. The reason is a simple one, management, engineering, supervision and technician robot weld process control – best practice expertise is almost as rare to find as an honest politician.

Management in companies such as Tesla, VW, Toyota and  GM The robot MIG who believe in front office / engineering process ownership,  will be glad to know that their robot MIG weld weld issues & the easy fix robot weld process control resolutions,  are discussed extensively in this  web site, (see robot sections) and the “required robot weld process control training / self teaching programs”  are provided for the cost of a good dinner for four.        

AUTO PLANTS, MANY ENGINEERS, LITTLE PROCESS EXPERTISE.  Lets face it, both car and truck global mfg. plants employ more engineers than most other industries and their weld manufacturing facilities. However the last place you would find  manual & robot arc weld process control – best weld practice expertise, is with the majority of weld decision makers in the plant’s front office.

When engineers  have a weld issue with their robot lines, their resolution will often be to rely on their lower paid, less qualified and often poorly trained robot technicians, or they will phone their distributor salesman  or robot integrator to help resolve the plant’s weld issues.

This  fire works display below  from the newly trained Detroit Big Three auto welders indicates not only poor training but also  poor manual MIG weld repairs being applied  on  the poor quality auto & truck  robot frame welds.

The norm plant’s weld practices for many global auto – truck frame and other parts welds.  Put poor manual MIG repair welds on top of poor robot MIG, welds. With present day multi-billion dollar recalls and liability concerns, lawyers should get exited with this simple mfg. reality.

Common auto & truck weld mfg. practice. Place poor
manual MIG repair welds on top of poor robot MIG welds.

Two good robot welds in a row in an auto plant, would be as rare as finding an honest politician.

Each year in North America typically 15 to 20 billion dollars are lost to the Auto and Truck industry major mfg, companies as a result of product defects, which lets face it have to be primarily influenced by  managers and engineers. Hundreds of millions of dollars are also lost each year with robot weld lines which typically are allowed to be run without arc and resistance robot weld process controls – best practice expertise.

The majority of cars & trucks resistance & MIG welds.
do not attain their weld quality – production potential.

Robot welders

Thanks to poor management, those resistance (spot welds) are also out of control, management solution, put many more welds on to compensate .


You may not want to ask a MIG weld COST question on the shop floor or in the front offices of  most global car and truck plants, and for that matter, dont ask in most other mfg. plants that provide manual or robot MIG welds.

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 and this sales person is often an individual who has never worked or run a weld shop.

AN INDICATION OF A PERSONS ARC  WELD PROCESS CONTROL EXPERTISE IS EVIDENT WHEN THEY CAN ATTAIN THE HIGHEST POSSIBLE MANUAL OR ROBOT WELD QUALITY WITH THE HIGHEST POSSIBLE DEPOSITION RATES:

An industry that lack process expertise will ask a salesman?

Inexperienced sales reps may not give accurate welding technical advice

What gas, wire, power source, process, weld transfer mode, consumables and parameters.  How many more decades will pass before weld industry management gets a grip on it’s processes and cuts it;s umbilical cord to the local  salesman?

Over the decades I have intensely disliked being in weld shops in which management has failed to recognize it’s crutch reliance on the use of  their local weld sales rep for weld process advice. The reality is few sales reps have extensive weld application experience, and even fewer have ever  managed a weld shop.

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


How often do they have to ask a salesman?

Salesmen do not have the answers for welding problems

All that’s missing with this character, is the box of donuts in his hand.

YOU HAVE LIKELY BEEN THERE AND DONE THAT:  It’s Monday morning, the local weld salesman who in most instances has never supervised or managed a weld shop, marches through the weld shop door with a box of donuts and a big smile. After  listening to the weld shop issues, the sales rep then presents information on his  latest, costly, bells and whistles pulsed power source, and then lets you know about his latest magic three part MIG gas mix,  or unique metal cored wire. One of these products is often presented as a  solution to the  weld department woes. Weld issues that in reality are generated by the front office and weld department’s lack of  weld process  control – best weld practice expertise.

If I am chatting to any plant manager I would ask, “are the weld  decision makers personnel and those weld team members in your  facility qualified to make optimum manual or robot weld equipment, consumables, process controls and best weld practice decisions, or are they simply taking up time and space?

A Report from the Automotive News  reveals.. 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,  (approx. the hourly production of a big three car mfg ). It had expected to build 1,500 in September alone and then ramp up to thousands 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 battery supply and with WELDING the mostly steel vehicles.”

Tesla Innovative Automotive & Truck design, yet a sad
manufacturing approach to their robot welds.

When it comes to robot welds, Tesla is having the same weld issues that the rest of hands off managers  and engineers in the auto industry have had for decades.

Nov 2017: As Tesla found this year, there is a large difference in the weld challenges when you go from  low volume robot resistance and arc weld production, to high production robot weld requirements.  Tesla managers may not be aware that they are not alone with this issue, as few of the million plus auto – truck robots utilized in auto – truck plants in 2017, will consistently achieve their daily arc or resistance robot weld quality or weld  productivity potential.

When poor robot arc or spot weld quality and production occurs, there will often be much finger pointing from both the corporate and plant’s  front office managers and engineers, to those on the shop floor as to the prime cause of  the robot weld issues.

AUTO & TRUCK MFG. AN INDUSTRY THAT FOR MORE THAN THREE DECADES HAS BEEN CONSISTENT IN THEIR ABILITY TO PRODUCE POOR ROBOT WELD QUALITY AND PRODUCTIVITY:

When it comes to  MIG and resistance welds, the global auto – truck industry is notorious for it’s hands off managers and engineers. Less than 10% of the auto industry weld decision makers are  aware of  how to consistently attain their robot MIG or spot weld quality – production potential, or are aware of the prime root causes of their plant’s daily, never ending weld issues.

THE MANAGER FAILS WHEN THEY DON’T PROVIDE THE PROCESS EXPERTISE NECESSARY FOR QUALITY – PRODUCTIVITY OPTIMIZATION.

As manual arc weld and robot arc and resistance weld process control – best practice expertise is easy to learn and costs very little to little to purchase. One might ask then why is are these programs not being implemented in all global weld facilities? The reason for the missing link is simple. If managers, engineers and supervisors don’t comprehend the root causes of their daily weld problems,  (process controls not taught in most colleges, universities or trade schools), then the key weld decision makers  will not be aware that this is an expertise that both  they and their shop floor employees require and should be trained in.

His  bloody play around organ has to go.

For approx. six decades, the industries that utilize manual MIG & flux cored  acquired a reputation as a PLAY AROUND with controls industry. So when the robots were introduced into weld departments, it’s only natural,  that the robot technicians would also play around with robots arc and resistance weld controls and the managers would not blink.

The common plant mfg.managers solutions to robot weld quality or production issues, will be  order more robots, add a shift, add manual welders to the end of the robot lines,  ship the parts to a tier one or two supplier,  or sweep the frustrating weld issues under the rug, and send the parts south to Mexico.

Three plus decades, & few global robots will each shift
attain their arc weld quality – production potential

When mfg. plants lack a process control expertise you would think it’s a management responsibility to see this situation is rectified.

As in common with most  global auto – truck mfg. plants, I believe the Tesla robot / manual steel and alum weld results simply indicates that their weld management, engineers and weld decision makers lack robot arc and resistance weld process control – best practice expertise.

Any mfg, facility should be viewed just like a ship.  If the ship has issues the captain is first in line for blame. If things are not run well in the ship’s engine room, who do you think is responsible? In contrast when something is screwed up with the weld quality and productivity in a mfg. environment, both the plant and corporate mfg. management has the responsibility to take process ownership and provide the resolutions, and the prime resolution is to ensure those that weld understand weld process controls and best pracices.

Don’t look for weld process control – best weld practice expertise and weld process ownership in the offices of most global car – truck plants .

Before any company  purchases weld robots, they should  first ensure the front office, maintenance personnel and robot technicians have the required robot arc or resistance weld process control – best practice expertise. In most instances they will not have this expertise. so managers have a responsibility to provide it  for them.

EXPERTISE STARTS WITH THE ROBOT PO: Through the robot purchase order a qualified management would ensure that the robot integrator selected proves that with the robot cell or line they provide that they can actually meet a minimum of four hours of the maximum production requirements with the specified weld quality. This  should be proven at the integrator’s  facility before final robot delivery and before final robot cell payoff.

Tesla calls, and what a bloody waste of time that was:  In the spring of 2017, I got a call from some high brow Science or Engineering Manger at Tesla, California. This manager had received my resume as the plants weld eng. He wanted to know how I could assist their new Model Three Production plant with it’s arc and resistance robot welds.

The TESLA  plant  was getting ready to dramatically ramp up weld production on the Model 3 from a few hundred per-month to hopefully thousands of units a month by early 2018.

Tesla and the evident lack of management / engineering  expertise.
As our discussion went on, I could quickly tell this TESLA manger had no expertise on the subject of welding. He started to ask me questions that you would ask some weld novice at a community college. I asked him had he read my 8 page resume, a resume that spells out why for decades I have been a manual and robot weld process control – best practice expert. My resume also spells out that I had developed unique process control and best weld practice training programs and provided process improvements in more than 1000 plants in 13 countries.

How many managers are aware that their experienced weld
personnel lack process controls – best practice expertise?

Ed now Em was asked to optimize either the robot and manual weld quality and productivity on these and many other product icons.

Solving weld issues at numerous facilities and different industries from Auto – Truck plants, Nuclear plants, Submarine and Ship yards, Medical equip or most recent assisting United Technology with their Space Stn. and Mar’s Orion Space Ship part.

Tesla and the influence of it’s unqualified mfg. 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 either resistance or arc robot weld production (from hundreds of cars to thousands per-month) would without question lead to arc and resistance robot weld quality – productivity issues that were way beyond the auto industry norms.

IF YOU DON’T HAVE THE KNOW HOW TO CONTROL A PROCESS WITH LOW WELD VOLUME PRODUCTION, WHAT THE HELL WOULD YOU EXPECT AS THE PRODUCTION RAMPS UP .

I spoke with the Tesla interviewer for another 30 minutes providing info. on my numerous robot past achievements, and my qualifications were such that the AWS asked me to participate in writing the AWS. MIG weld specifications.  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 with an idiot”  and hung up.  Six to seven months later, the following indicates that Tesla is having more than a few robot weld issues.

From Em: Tesla will nave many parts built in Asia and consumers should be aware that as the customer for the parts its the responsibily of Tesla to drive the weld quality standards that should be applied espaeciall with costly and high milage warrant products. If Tesla cant control the weld quality at its CA plant, well figure out what consumers can expect as the miles pass by.

As Fruehauf and Volvo are aware with their costly tractor-trailers product durability may be more important than $250,000.00 driver-less trucks with laptops in a cab along with a generous battery mileage range. In contrast to cars, when these companies  build trucks apart from the power train many of the  welded components may be part of a 1 million mile truck warranty. Unfortunately in 2017,  the arc and resistance robot welds required on global trucks are  still after decades of truck building  experience,  causing many issues that impact, production quality and liability for 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 and engineers  in the auto – truck  industry have never had,  and it’s sad to say that in 2017 they are still in the dark.

Tesla, unique truck design, but what about robust mfg? It’s one thing to build cars with a 50,000 mile warranty &
then build trucks that wont rattle from bad welds within
the usual one million mile warranty.

Should there be concern with the Tesla weld mfg.  approach reference the truck’s longevity and  durability?  A 2017 note from me to Mr. Musk not that he is ever likely to read it.  Mr. Musk, with all respect, you have many admirers and I am one of them. Many of us love your  unlimited vision on technology products and life and especially what you have achieved at Spacex, , however as you are no doubt now aware  it’s easy to put your  concept vehicles on a pedestal and like the great salesman you are get investors and share holders exited. It’s another thing to successfully build those products within the production, quality and cost projections. The auto – truck steel – alum welded products that you are  involved with will be influenced by numerous ongoing variables from press / die wear, part / fixture design and process / robot weld mfg. expertise.  Please don’t get to frustrated  as you struggle today with your low production figures, as it’s going to get far worse as you ramp up.

Free Advice to Tesla

Mr. Musk you did not ask for advice and your company believes I was not qualified to give it, but here’s some free weld advice anyway.

You may first want to be aware that if the auto giants had the necessary talent to be successful in their daily arc and resistance quality – production goals, they would not require their tier one / two part suppliers to do it.

If the tier suppliers were highly competent in managing their weld processes, they would not daily have so much weld production / quality issues and have pallets full of rejects and rework.

Watching a one minute online video of your plant’s robot resistance  welds, I note that the robots appear to be too few and at approx. only 20 – 30 % of the robot weld speed potential.

The resistance welds look like they are at the design spec locations only, soon you will learn that you will need to compensate with many more welds. Also the power settings appear to be too  high, evident by both the expulsion and sound.Note:  Most auto companies are aware that for many of the resistance welds they need, they had better put two or three welds to compensate due to the lack of ability to consistently control the robot TCP, the changing part dimensions and weld locations and also eventually because the plants  will lack the discipline, expertise and ownership ability to manage and maintain the optimum tip configurations, weld parameters, part fit and cleanliness.The good news Mr. Musk is when the weld  production costs are driving you under, as the big three are aware, when weld problems occur with USA manufacturing, the company can sweep the problems under the car mats and ship the parts and robot lines to Mexico, (Chrysler was very qualified at doing this).


STEVE JOBS WAS  A VISIONARY,  I BELIEVE WHAT MADE HIM  UNIQUE WAS THAT HE IMPACTED BOTH THE DESIGN AND THE PRODUCTION METHODS REQUIRED TO TO THE QUALITY INTO THE PARTS BUILT.


Tesla and Spacex
.  Some may see the  irony in an organization such as Tesla not being able to provide the process controls – best practices necessary for simple  robot resistance and I suspect arc steel welds on low volume car production. Yet at the same time Elon is responsible for SpaceX, a company that should be producing  the highest possible  weld quality on the space craft components. The weld engineers at SpaceX will be using old TIG technology,  and likely be of little help if  asked to assist with the robot resistance and  MIG welds at the Tesla plant.
Last word to Elon. Next time your company wants to hire a process expert, make sure the person your company designates to do the interview, has at least some knowledge on the subjects discussed.

MAGNA one of the top three global auto part suppliers: Below, Ed providing Robot Best Practices – Process Control Training for robot personnel at a USA company called Magna, This company in 2016 was  which the 3rd largest global  tier one auto – truck parts supplier. At this US MAGNA facility, I started the MIG robot process control training program in one of the manual welders cell. Learn the process before you adjust the weld on the robots.

When you train robot techs in robot MIG process
controls, you start the training in a manual MIG weld cell.

Ed teaching MAGNA robot techs on how to control robot MiG welds. Step 1. classroom, Process Controls. Step 2. Hands On. Step 3. In put lessons learnt in the robot cell programs.


Over time,  I was requested to assist a few North American MAGNA facilities, and in my visit weld evaluations came to the conclusion that the robot, MIG weld, process controls and best robot weld practices requirements was not well understood by the either  the MAGNA corporate or plant management and engineers that were involved in the daily robot weld decisions. As for the young engineers and technicians that daily kept the robots working, the majority of the guys I met, knew plenty about robot programming, but hardly knew anything on the subject of MIG weld best practices and  weld process controls. 

The best thing that the engineering management at MAGNA for their robot MIG lines and for their robot techs, was provide parts to be welded that actually met the design dimension requirements, this by the way was the first company I had ever seen in the auto – truck industry that had the metal stamping ability to provide good parts for welding. When robot parts fit without serious weld gaps, robot welds become easier to achieve and even inexperienced robot weld  technicians tend to get better weld results.

My robot MIG weld process control – best practice program. Teach your self, or use to train your employees.  Click here.


Another costly robot application. High spatter MIG data
is another indication of poor robot weld management.

Imagine the costs associated with these poor welds and the small price for process controls that lead to process optimization


SO YOU KNOW HOW TO OPTIMIZE ROBOT MIG WELDS?
  If you know MIG weld process controls,  and that the MIG wire size utilized for the above welds was 0.052, (1.4mm). The gas 90 Argon – 10 CO2, and that the single pass, fillet welds were 5/16, (8mm).  A weld process professional would be able to look at this photo and instantly be aware of the CV Spray wire feed rate or the optimum Pulsed MIG amps plus the approx. weld volts and robot weld travel rate. And then in a few seconds determine what the weld issue in this photo indicates and what the weld solution is.

When management, engineers, supervisors and technicians lack an expertise required for the processes they daily utilize, this may  create the following;

  • their weld facilities will rarely attain their optimum weld quality – productivity potential or understand their real weld costs,
  • their weld facilities will frequently rely on weld equip – consumable vendors or inexperienced sales reps for assistance with their weld issues, these are personnel that will rarely have worked or managed a weld shop,
  •  their weld facilities that constantly search for  a new crutch for their weld issues. The crutch may be the purchase of a new sophisticated costly pulsed power source that’s often loaded with useless electronic bells and whistles. Or the purchase of useless three – four part gas mixes,
  • their weld facilities will have to add to their manpower or pay overtime costs to attain the required production and rework,
  • their managers and supervisors will  daily  be in the FIREMAN mode, forever fighting but rarely resolving weld quality – productivity  issues,
  • their weld facilities will lack the ability to develop a weld  team that can quickly enable cost effective resolution consistently attain process optimization,
  • their  weld shop culture produced will fear process change,s and therefore will avoid or not embrace the effective process evolution,
  •  their weld department will build up their QA dept personnel and budget, and place their  mfg. quality focus on FINDING rather than PREVENTING weld defects,  (never has been cost effective). NOTE: It’s logical if a company  employs weld inspection personnel that management should ensure they are provided with weld process – best practice training, something that 99% will not have. .Click here for your MIG – TIG – TIP TIG or Flux Cored  weld process optimization training or use as self teaching materials

Dana USA. The world’s best selling  Ford F-150 trucks.

2007 E-Mail from R. Good. Weld Engineer Dana USA.
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 100% of the frames required extensive manual weld rework.

Ed thanks to your Robot Weld Process Control Best Practice Training program, and the weld process, consumable and practice changes that you recommended and we have now across the board 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. Ed we have now provided your robot training program and implemented your robot weld process recommendations in five of our USA plants.
Many thanks Ed…… RG Dana.

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. By the way for these changes I would have charged Dana less than $10K and I never got a thank you note from Dana or Ford senior management,  both of which I am sure never even understood what I did for them.

My Beetle welds at Johnson Controls,  Mexico:


When the new VW Beetle was introduced  it was announced that this iconic vehicle was going to be built in Mexico for obvious reasons. The contract for the Beetle seat frames was given to Johnson Controls (JC) Mexico. After the new ABB MIG welding robots were installed at the JC Mexican plant, for many months, the JC Mexican and US engineers struggled and could not meet the VW destructive weld test requirements for any of the Beetle car seat welds they produced.

THE  VW GERMAN MANAGERS SCREWED UP,  The robot MIG welds at the Mexican facility were strictly being carried out in accordance with the robot weld specifications / procedure requirements that were from VW Germany. I was requested by JC USA to provide the robot weld resolutions for the seats.  When arriving at the  plant, I immediately figured the German robot  MIG  procedure parameters were too low, and this was effecting both the destructive test  weld quality desired and also reducing the robot productivity potential.

In the 3 days I was at the facility I  completely changed the robot weld program,  the weld transfer modes, the consumables, parameters and practices. I eliminated all the weld rework and as a bonus I gave them an  increase in  the daily robot shift weld production by 40%.

Of course with the major weld changes I made,  the Germans requested that I stop making the changes and urgently attend a meeting in which all German / Mexican responsible managers and engineers must attend. Of course I followed orders. At the meeting the VW executives went on for an hour about how important it was to for the Mexicans to produce their parts in accordance with their pre-approved specifications and procedures from Germany. They said that I must not make changes. Of course after dealing with Germans for decades,  I had my big guns ready. (don’t talk show results).  Before the meeting I had sectioned one of their prototype robot MIG welded car seats that were welded  in Germany,  the German seat weld macro’s revealed  that over 60% of the small seat welds had extensive lack of fusion. I then showed the same macro welds from the changes that I had made on the Mexican produced seats, my changes revealed that the fusion defects were gone. I then told the VW mangers that I had also increased their robot shift weld production figures by 40%.  I asked them should I change the robot data back to the German requirements, for some strange reason they went very quite. The German managers who would not have known a good weld if they found one on their dinner plate  mumbled something about approving my changes. They quickly left the building with their tails between their legs. I think for my quality – productivity improvements and for  their management  BS, that I charged  them around $6000.

MORE ON MY BEETLE SEAT WELD QUALITY. Around 1999 to 2000, the USA Insurance Institute for Highway Safety, in it’s car crash tests rated the Beetle car seats (those using my robot weld data), as the most durable of all in the small car seats they had ever crash tested.

Viza car seats in the beautiful town of Vigo  Spain:

In Spain and other parts of Europe,  Ed improved robot car seat and other welds on BMW, VW, Jaguar, Toyota, Renault, Ford, GM.

Viza builds  auto – truck seats for  Toyota, Renault, Citroen, BMW and others. The president and owner of Viza requested that I come to Spain, I jumped at this request at as it was certainly much more pleasant than going to  Detroit car facilities. The owner of Viza  had started to invest heavily in new robot lines  for his products and he requested that I resolve his companies robot seat weld quality – production issues and establish my Best Weld Practices / Robot Process Controls for his companies  employees and new robot MIG weld lines.

In the two weeks I was at the Spanish facility I  established highly success robot weld quality – productivity results with all the robots. I then trained the Spanish employees with my robot MIG weld process control training program. Was this a sucess, a few years later I was requested to return by the Viza owner for the start up of two more of his new plants, one in Spain and the other in Eastern Europe.

Tier One Tenneco – Monroe USA and Global.

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.  eds_training_materials

Ed’s influence on Caterpillar Trucks & Elgin Sweepers.

When the world’s largest truck was first built, Ed was as the  ABB Weld Manager, and was asked to  establish the robot weld data.

E-Mail: Hello Ed now Emily I believe congrats on that big change and change is something you were never afraid of.  I know you set the robot welds on the Caterpillar world’s largest truck and as you know In the past I purchased your Manual MIG weld process control – best practice training resource for the Caterpillar plants that I was assisting. To get you updated,  I recently  purchased your Robot MIG weld process control training package for Elgin Sweeper Company here in Illinois. Em your programs worked wonderfully at both Caterpillar and at Elgin. We were very successful after implementing your Robot 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 outstanding. All the best Em. Regards  Joe Cukierski. Weld Mfg. Engineer. Elgin Sweeper Company.

In the USA, we did not just loose jobs to NAFTA and other lower wage countries, we also lost a tremendous amount of good paying USA manufacturing jobs as a result of ignorant, self centered, politicians, and to  Fortune 500, manufacturing & process, management and engineering, ignorance and incompetence, as described at Chrysler  below.


My experiences with the 20 plus million dollar,
Chrysler, Corporate, Management, Neon Fiasco.

Chrysler and its pathetic approach to robot welds.

On my favorite  subject of manufacturing management incompetence, in the nineteen nineties, in a period of less than 18 months, Chrysler corporate management lost  15  – 20 million dollars from a new, flux cored robot line. This line was located at the prime Mini Van stamping facility in Ohio.

The robot weld line at the Ohio facility was designed to weld the Neon cross-members. From the day it went into production, this line never made more than 50% of it’s daily robot weld production goals and it’s  daily robot weld rework was 100%. The robot welds were made with Lincoln, Self Shielded, (SS), Flux Cored wires.  Please note this is a weld wire that Chrysler made many of it’s tier suppliers use. It was a pathetic excuse of weld consumable choice made by the corporate Chrysler weld engineer.

The sad excuse for the SS weld consumable was influenced by Lincoln Electric. The frustrated, Chrysler stamping plant manager had requested Lincoln engineers provide help with the sad robot welds. Eventually the Chrysler plant manager gave up on the Lincoln engineers and his own corporate weld engineer, and requested my assistance. In less than 3 days of robot weld process evaluation on the large robot lines, I came up with a weld process solution to fix all the welding issues. The majority of the weld issues were a result of the Lincoln SS wires,  and complete lack of weld control expertise by all the mangers and engineers involved.

When my resolutions were presented on the root causes to the senior Chrysler management, for self preservation reasons the Chrysler corporate weld engineer declined to admit that he had made at that time a  14 million plus dollar mistake in his selection of the world’s worst weld process and consumables. These are weld wires better suited for farm work.

I recommended to the Chrysler plant manager that to convince the Chrysler corporate engineers of the of the folly of the  poor  process selection, that we do the robot welds with MIG using the same poor fit Neon parts . The plant manager gave permission. I then produced the sample parts. I  provided a 35%  increase in the robot line weld productivity with no weld rework required. I had the parts weld and part strength tested by the largest weld testing agency in Detroit. They reported that the welds and parts met the design requirements and had no defects.

For that lack of ownership Chrysler engineer to accept my weld process changes would have been an indication that he was responsible for the multi-million dollar robot weld issues. He argued against my recommendations with his corporate peers, (this was the blind leading the blind) that changing to MIG process would be a mistake. And the plant was told to back to using the poor SS wires. A few  and a few months with the Neon weld over costs now around 18 million dollars the over-paid Chrysler management team made a gutsy engineering decision. The Neon stampings and the new robot lines  were to be  loaded into trucks and shipped out of sight to a plant in Mexico.

The reason for the robot line shut down and loss of these USA mfg. jobs, was not a result of  cheaper Mexican labor, the reason was the Chrysler management and engineers involved with the project;

[a] lacked the ability to design parts suited for robot MIG  welds,
[b] lacked the ability to build parts to their own design dimension tolerances,
[c] lacked the ability to make rational weld process and consumable decisions,
[d] lacked the ability to establish effective robot weld best practices – process controls.
[e] lacked the ability to stand up to an inexperienced  weld engineer who’s ego and lack of expertise was the root cause of the multi-million dollar issues.
I visited the Mexican plant a year later, the Mexicans were simply manually welding (same lousy SS process)   over every robot weld on the Neon parts. The bottom line  was bad welds on top of bad welds, but the welds were now out of site in that plant  in Mexico. More on the Chrysler Story:

Robot industry norm, PLAY around with the weld data.

Just give him an hour or two to “play around: with the weld controls.

 

As mentioned a million time, no other industry uses more arc welding robots than the global Auto – Truck industry. In my position one time as Weld Manger the largest North American  Robot Mfg, I found the following robot MIG welding facts;.|

Management influenced automotive robot weld issues.

Average global “real world” robot MIG weld down time is 40 to 70 minutes per-shift. This data is often unknown by the responsible managers as it’s not correctly reported or documented. With weld process control expertise, the average robot down time per-shift  should not be more than 15 minutes.

Average global robot weld rework per-shift,  25 to 75 %.  The frequent  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 high volume  weld rejects is 5 to 50% per-shift. Management solution, attain a contract with a local scrap dealer,  hire more manual welders to respond or simply fudge the daily weld reports, With weld process control expertise it should not be more than 2%.

Average robot weld production efficiency per-shift. 40 to 60% of the real weld potential. Cannot be maximized without robot weld process controls – best weld practices. Management solution provide manual overtime or purchase more robots.

The irony with the above pathetic robot weld results 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 robot MIG process, the robot technician should understand and optimize four distinct MIG weld transfer modes. Understanding the weld modes, the optimum weld consumables and weld / wire parameter ranges, and then matching the best  weld data and robot weld practices to the specific weld application or problem, is logical expertise for both the robot technicians and and front office weld decision makers who have an opinion on the welds.

If this sounds complex, please note that using  my process control training materials,  you only have to learn three simple MIG or flux cored weld settings and a few Best Weld Practices to consistently attain optimum weld quality – productivity on any manual or robot MIG weld application.

THE SAVINGS WERE OFTEN MEASURED IN THE MILLIONS: 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 controls and establish the best practices. Then I would provide one of my  training Programs. What I thought was ironic in many of the plants that I was requested to provide 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 manual or robot weld 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 the front office decision makers and supervision  took an interest, and attended the short process improvement training programs.

For weld process controls to be effective, all those involved with the plants weld decisions have to walk the same path to weld process optimization.

Car robot welds, or manual Aerospace / Defense product arc welds.  With arc weld process control expertise,  the industry is not relevant as there is only one way to weld with the process selected.

I would use the same process control logic for
welds in a Nuclear Plant, as I would in a Car Plant.

It may be 2018, but  STICK or TIG with 1980 specs. and procedures are fine. 

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

Over the years Ed / Em  has been asked by the following industries to improve their manual / automated weld quality and productivity. Nuclear, Defense, Oil, Nat Gas, Power, Sub Sea, Ships – Submarines and Medical equip applications. She also was asked to improve the GTAW weld quality on USA Fighter Jets engine cast bodies and welds on the Mars Orion space ship

WHAT A WASTE, MILLIONS OF DOLLARS LOST DAILY  WHEN WELDERS  PUT THE WELDS ON, THEN GRIND THE WELDS & SPATTER OFF.

Lack of process expertise often means high grinding
wheel costs and unnecessary labor costs.

So whats new, another auto part weld out of control.

In the global weld shops, in which the front office personnel lack  process expertise, 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 responsibility for the management, is to ensure that their play around welders do not run out of the never ending grinding discs that are required. You can be sure in these plants that no one is adding up the costs of weld rework and weld cleaning..

Oil Tankers, LNG vessels, Frigates or Aircraft Carriers, always  major weld / alloy issues and the sad reality is too many managers & engineers that don’t know how to respond..

Unnecessary weld repair costs, & poor weld production
is the norm, so it’s easy in any ship yard
to save millions  of dollars per-ship.

Duplex – Stainless, Nickel and Cu alloys, all easy to weld with TIP TIG.

I have been a weld manger in a Ship yard and advised on Submarine and Navy frigate weld issues in Europe, the US and Canada. The bottom line at all of the facilities that I visited, was I never found a manger or engineer that truly understood weld process controls, best weld practice requirements, and none of the key weld decision makers had the ability for weld process ownership.

I believe that if you want to find the world’s worst welds, produced at the highest unnecessary weld costs,  simply visit a yard that makes ocean going vessels.

In the ship yard that I manged, through my flux cored process control – best practice training program, and by educating the management, engineers and supervisors, I reduced the ship flux cored weld rework costs by sixty percent and that represented millions of dollars in savings per-ship.

Over the last three decades I created the required weld process control – best practice training or self teaching resources. I then made the costs of those resources very  low (< $300) at prices  even the most tight fisted manager  will only grumble a little about paying this exorbitant weld costs. And to improve code quality and alloy welds, I also bought the TIP TIG process to North America and Australia. 

CLAD WELDS. Complex ASME  Clad weld applications can be simplified with the use of weld process control expertise:

ASME quality clad MIG welds on Water Wall Boilers.

When Ed  established his patented approach to Pulsed MIG , automated, water wall clad welds, of course he produced welds with complete control with major weld and boiler cost benefits.

As the weld manager at WSI (Aquilex) Atlanta,  I established a new pulsed MIG  weld stainless / inconel clad patent. WSI is the worlds largest cladding producer for Water Wall Boilers.  Take a close look below my untouched Pulsed MIG, vertical up, inconel, single pass, water wall, clad welds attaining less than 7% weld dilution.

My Pulsed MIG patent attained 16 lb/hr, single pass,
less than 7% dilution. Welds untouched. Covering large boiler water walls. A new patented MIG  clad weld  from Ed. The power industry had never seen this quality with the cost savings.

The above  clad welds would cover large water wall boiler areas typically from 1000 to 5000 sq/feet. To get the required single pass clad  welds with more than 20% chrome content in a single weld pass, it was important that the clad weld  must achieve less than 7% single pass weld dilution.

Read how in the nineteen nineties. Ed’s USA – Europe “Pulsed MIG Overlay Clad Weld Patent” improved global boiler, water wall, clad weld quality. My clad patent reduced the global, boiler wall clad weld (inconel – stainless) consumable costs by  a minimum of 25%, and the superior, uniform weld quality and weld pass tie -ins reduced weld defects and stresses and increased the boiler life longevity.

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.
[] Most weld rework,  rejects or distortion concerns.

Managers or supervisors that would take more than 5 minutes to work out the cost of a weld,

FOR MANY WELD SHOPS, WELD COST SAVINGS CAN BE EXTRAORDINARY: Over the last four decades,  in the numerous global plants I provided weld resolutions for, I readily generated over 250 million dollars in arc weld quality – productivity improvements, and those are savings that usually continue for years.

APPLICATION DIVERSITY BENEFITS FROM PROCESS EXPERTISE. 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 quality – productivity issues. I have also managed Ship Yards advised on Submarine, Aircraft Carrier, Nuclear plants welds and the Mars spacecraft.  It did not matter what the code utilized or the weld 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 while chatting 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:

WHO HAS THE PROCESS OWNERSHIPY?

Administration and management need to take responsibility for weld quality, too.Forget all that other BS and try a new 2017 mfg approach to weld optimization. Its called Management process ownership & accountability.

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 when you need a weld  opinion. 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 below shows the robot MIG parameters are not close to optimum. It would take 5 minutes to fix. The reason this robot issue was not likely addressed by the robot technicians is simple. They lack weld process control expertise. They will continue with their lack of expertise till someone in the front office wakes up to the expertise required by them and their shop floor employees.

Robot MIG fire works display, shows incorrect volts.

The robot MIG parameters are not optimum Hundreds of thousands for the above robot cell run by weld techs with no robot weld process control – best practice expertise.

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.

WHY ARE YOU GUYS PLAYING AROUND WITH THE WELD CONTROLS?
You must have heard these remarks before, “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 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 – Power industry facilities.


2017 Oil – Gas – Power stuck in the 1960’s.

Many Oil – Chemical Ind. engineers, know how to inspect weld quality,  but few have the arc process control – best practice expertise that’s required to consistently provide the best possible weld quality with the lowest costs.

 While these industries demand high weld quality you will find in the front office and in the pipe / vessel weld departments, the prevailing MIG – Flux Cored and now TIP TIG lack of weld process control and best practice expertise. Yes they have weld QA departments that like most focus on finding rather preventing weld defects. Most QA personnel will have the ability to evaluate the quality of the weld, few will have the weld process controls – best weld practice expertise to ensure consistent, uniform weld optimization

It’s sad when managers & engineers in high tech industries will leave their weld optimization, costs & weld evolution to those on the weld shop floors.

                                     Can you count the weld safety infractions?

If you are a process expert, have a go with
some of the MIG – FCAW  questions below.

E Craig’s MIG Weld Process Controls Test.

E Craig’s Flux Cored Process Controls Test.

This site was established around 1998 and this is only the home page. 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 MIG – TIG – TIP TIG and Flux Cored process control resources required for process optimization, the lowest weld costs and to reduce their weld liability concerns. Lets face it, who wants to watch experienced weld personnel PLAYING AROUND with their weld equipment controls. Click here for your weld process optimization materials

An Aircraft Carrier may cost 13 billion dollars, but it will be very difficult in the ship yard to find managers who could tell you the cost of a  simple 1/4 (6 mm)  MIG or Flux Cored fillet weld, or tell you what the average daily weld deposition  should be for one of the yard’s flux cored welders.

In this industry, few front office mangers & engineer
will understand the concept of Weld Process Ownership.

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 costsHow much for over budget weld rework and repair costs,
60 – 80 – 100 + million dollars, and the weld mgr was where?

Its easy to criticize,  but the weld reality as I did at numerous locations, it would take me less than two hours at most facilities that weld to prove that daily the facility does not even come close to the weld quality and productivity potential that with a little process expertise they could readily attain.

With Ed the weld application did not matter.

Ed repairing Textron (Florida mfg.) Stingray Tanks in Thailand

Textron management, engineers and supervisors did not do their  job, so they requested I go to Thailand and manage the necessary weld repairs on the 270K tensile Stingray Tanks.  I spent many months in Thailand managing the numerous tank repairs and also training the Thai Army,  (the soldiers had never welded) on how to do produce optimum MIG and Flux Cored welds. In my  ten day process control – best practice training program, the Thai solders  produced MIG and flux cored weld quality that was superior to that achieved by the welders  (lacked process control training) at the Florida facility that built the Tanks.

From the manual Stingray Tank welds to optimizing the robot Frame welds on the world’s largest selling Ford F-150 trucks. From establishing the robot welds on Harley and Indian bikes, or resolving weld issues on Spacecraft  or Air Craft Carriers, for me  the application was not that relevant,  it was always about the process control and best weld practice requirements necessary to control the weld pool and then passing that expertise in a simple manner to the different plants.  My training – self-teaching Resources, are now in use by more than 3000 companies in 27 countries.

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..


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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.



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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..

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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.

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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)