Weld Reality Home Page 2.
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THERE SHOULD BE LESS CONCERNS FOR MIG & FLUX CORED WELD PRODUCTIVITY, QUALITY, REWORK, REJECTS, RECALLS AND LIABILITY ISSUES, WHEN THE PROCESS CONTROLS & BEST PRACTICES AVAILABLE AT THIS WEB SITE ARE IMPLEMENTED.
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ALL COMPLEX WELD APPLICATIONS ARE SIMPLIFIED WITH WELD PROCESS CONTROL EXPERTISE:
how in the nineteen nineties. Ed's USA - Europe "Pulsed MIG Overlay Clad Weld Patent" which he developed
for WSI (Aquilex) Atlanta,
dramatically improved global boiler, water wall, clad weld quality. The new weld cladding dramatically reduced the global, boiler wall clad
weld (inconel - stainless) costs, and increased the boiler life longevity, click here.
AN INDICATION OF MIG WELD PROCESS CONTROL EXPERTISE WILL BE EVIDENT WITH WELDS THAT HAVE ATTAINED BOTH THE HIGHEST POSSIBLE WELD QUALITY WITH THE HIGHEST POSSIBLE WELD DEPOSITION RATES:
Ed's untouched Boiler Water Wall Clad Welds:
Take a close look at my 's
untouched pulsed MIG, vertical position, inconel, single pass, water wall, clad welds. The clad welds would many times cover large water wall boiler areas > 2000 sq/feet, and the single layer welds would always when tested indicate less than 7% dilution. This single pass, low dilution weld would acheive > 20% chrome. The " untouched", spatter free, single MIG torch weld deposition rate, was approx. 15 - 16 lb/hr.
REMEMBER INCREASING WELD DEPOSITION RATES INFLUENCES THE ATTAINABLE WELD SPEEDS. INCREASING WELD SPEEDS IS USUALLY THE MOST LOGICAL METHOD TO REDUCE WELD HEAT AND DILUTION. THE MAJORITY OF ALL WELD APPLICATIONS, ESPECIALLY ALLOY WELDS, TYPICALLY BENEFIT FROM ATTAINING THE LOWEST POSSIBLE WELD HEAT.
THE GENERAL MANAGEMENT CONFUSION ABOUT "WELDER SKILLS" AND WELD PROCESS CONTROL EXPERTISE: When I am explaining to management or engineers why their personnel need Weld Process Control Training, a common response is, our guys dont need that as "most of the welders are highly skilled" and some have been welding for two decades.
They say this while they daily watch them play around with their weld controls..
Most managers, engineers and supervisors are simply not aware that manual welder skills has little influence on attaining consistent, optimum, manual and robot weld quality and productivity. You do not want to ask those exp manual welders to provide you with the weld data that a robot requires to make a common weld.
Optimum manual - robot welds are established through the primary weld decision maker's Best Weld Practices & Weld Process Controls Expertise. This is the expertise that I have taught for decades. This is the expertise that as of 2014, is still not taught in any global University or College that teaches Weld - Mechanical Engineers and Technicians. It's an expertise that since the nineteen nineties has been available at this web site. Ed's Best Weld Practices - Weld Process Control Resources.
following are a few of the companies that I generated dramatic
weld cost reductions through manual / robot weld process optimization.
Ed optimized the above and many more robot - manual MIG applications.
A FEW OF ED'S APPLICATIONS: Harley - GM - Corvette - Volvo - Ford / Chrysler - Subaru
- Volkswagen - Mercedes - Honda - GE - ABB-Westinghouse - Babcock - Textron -
General Dynamics - Imperial Oil - Combustion Engineering - Hydro Aluminum - Hayes
Lemmerz - Fruehauf Trailers - Case - Club Car - Genie - Sky Track - Manatowic
- John Deere - Caterpillar - Johnson Controls - Monroe.
With the common weld processes such as MIG, Flux Cored and SMAW, and the ever increasing, extraordinary amount of costly poor weld quality that is produced daily, the
potential for catastrophic
failures and product liability issues dramatically increases each year.
the industries that utilize the MIG and flux cored weld processes, hundreds
of millions of dollars are daily spent on unnecessary NDT costs, weld rejects
weld rework and poor weld productivity.
If anyone in the weld industry has doubts
about why anyone in this business should be concerned about the overall, poor, global MIG - flux cored weld quality and productivity,
they first may want to take trip to my "Bad Weld" section, and then also take a few moments to read about about the extremely poor self shielded (SS) flux welds that were responsible for many of the buildings
and bridges that toppled during the last
major earth quake in California. Most of the California structures were designed to stand erect during seismic loads, and these easily collapsed due to the use
of unsuitable Lincoln, Self Shielded flux cored wires, in combination with poor weld practices and
inexperienced designers, construction supervisors, engineers, project managers and welders, personnel who were
and likely still are not qualified to make sound weld process decisions.
From auto - truck plants to refinery pipe welds, it's never difficult to find evidence of lack of best practices and process controls.
year was 1984. I was asked to consult for one of the largest oil refineries in Houston. At the refinery, a new section
was about to be added. The pipe project required over a thousand pipe welds. At
the refinery, there was great resistance from both the engineers and project management
to using the cost effective, all weld position, Gas Shielded, Flux Cored wires.
In contrast, the this is the way we have always done it engineers, wanted to stay in their comfort zone and use the traditional SMAW (stick) process for the pipe
fill pass welds. The engineers were not concerned that the use of the gas shielded flux cored process, would
have created for their company superior weld quality with weld cost savings of approx. two million dollars for the project.
I don't suppose you ever heard the
statement from weld personnel in your fab shop.
IN THE CODE QUALITY WELD INDUSTRY THAT TYPICALLY WELDS PIPES AND PRESSURE VESSELS, YOU WILL HEAR
MANY MIG AND FLUX CORED WELD
OPINIONS, YET FEW OF THE OPINIONS ARE BASED ON WELD REALITY:
1984. In a weld report I presented to managers at one of Houston's largest refineries, I wrote the following: "On the subject of weld process quality and productivity optimization for your
new installation. During the weld meetings I attended
with your contractors, project managers and engineers, I hope you are aware that the managers and engineers that were the most vocal against the utilization of the highly
cost effective Gas Shielded Flux Cored process, were the least qualified in the meeting to have any opinion on any weld process".
Management and Liabilty Consequences from
Lack of Weld Process Expertise and Ownership.
It's unfortunate that on the majority of major global weld applications, that few of the responsible managers and engineers have the weld process control knowlege
to daily ensure optimimum weld quality at the lowest weld costs.
executive in an industry that daily deals with critical weld applications,
should ask the following fundamental question. Do
the managers, engineers and weld decision makers in our company, daily hold themselves fully accountable
for the quality of our products manufactured and do they also fully understand the equipment and processes utilized?
2015: THE COST CONSEQUENCES FROM INEXPERIENCED DECISION MAKERS..
During the last thirty years, those weld managers, engineers and supervisors who lacked MIG and flux cored weld process expertise, unfortunately drove up their companies weld costs and ensured that their
code quality, vessel
and pipe applications and their weld shop was stuck in a 1950 - 1960's TIG and SMAW process time warp.
You would be astonished to find that in the next decade, many global chemical
plants, refineries and, power plants will be constructed using SMAW (stick) and the regular TIG process as the primary weld processes. The prime weld procedures
utilized to build these billion dollar projects today and in the last three decades were likely
in most cases based on the Stick and TIG weld procedures that were first established between 1950 - 1975. How many of the engineers at these projects gave consideration to flux cored and how many engineers knew how to optimize the flux cored process,
I wonder how long it will be before code quality weld projects wake up to the fact that for a few years now their is a much more cost effective, easier to
use pipe weld process that will attain superior manual and auto pipe welds than TIG - MIG or FCAW. This is a process that my partner and I bought to America, its called TIP TIG. (www.tiptigusa.com).
2007: DOW CHEMICAL AND LACK OF WELD ENGINEERING EXPERTISE:
I had just visited a plant in which Dow, one of the USA largest chemical companies had requested that a 3 inch (75mm) thick, 304
stainless nozzle, approx. 8 feet (> 2 m) in diameter, was to be welded with 1/8
(3.2 mm) diameter STICK electrodes. Over the years I had seen this many times with large DOW weld applicaIions. It was my impression that the corporate management
at Dow were simply not aware that for decades, many of their engineers and
project managers have on construction projects and applications dramatically increased
the Corporations weld labour costs and jeopardized the application's weld quality. With most applications the Dow managers / engineers would insist on the utilization
of SMAW (stick) or GTAW. These engineers were either not comfortable with, or had ignored the MIG - Flux Cored and TiP TiG process.
IT'S UNDERSTANDABLE, (BUT NOT ACCEPTABLE) THAT WHEN ENGINEERS AND MANAGERS LACK WELD PROCESS CONTROL - BEST PRACTICE EXPERTISE, THAT THEY WILL LIKELY WANT THEIR WELD APPLICATIONS WELDED THE SAME WAY THEY WERE ORIGIONALLY WELDED IN THE 1960S.
THESE WOMEN QUICKLY REVEALED A FEW
FACTS ABOUT WELDER SKILLS:
How important to any weld shop
Weld Process Control & Best Practice Expertise?
THE UNNECESSARY GLOBAL MANAGEMENT CONCERN, FOR THE LACK OF SKILLED WELD PERSONNEL:
PICK UP A WELD MAGAZINE OR READ THE BUISNESS SECTION AND BEFORE LONG YOU WILL RAED ABOUT SOME IVORY TOWER EXECUTIVE COMPLAINING ABOUT THE SHORTAGE OF MIG - FLUX CORED OR TIG SKILLED WELDERS..
THE WELD REALITY IS THIS: ANY COMPANY WHO DECIDES TO EMPLOY AN OPEN MINDED, DRUG FREE, ENTHUSIASTIC INDIVIDUAL WITH "ZERO WELD BACKGROUND", COULD USING MY EASY TO USE WELD PROCESS CONTROL - BEST PRACTICES TRAINING RESOURCES ACHIEVE THE FOLLOWING.
WITH SOMEONE WHO HAS NEVER WELDED, IT WOULD TAKE 5 TO 8 DAYS TO TEACH AND TRAIN ANYONE WHO HAS A STEADY HAND TO MEET ANY CODE PIPE OR STRUCTURAL WELD QUALITY REQUIREMENTS WITH EITHER THE MIG - FCAW OR TIP TIG PROCESS.. View Ed's MIG - FCAW Best Weld Practices - Process Control Resources.
WELDERS, PLEASE DON'T GET UPSET WITH ME ABOUT THE ABOVE STATEMENT. LET'S FACE IT, IF YOU ARE A TRUE WELD PROFESSIONAL YOU WOULD BE AN INDIVIDUAL THAT COULD "WITHOUT PLAYING AROUND WITH THE WELD CONTROLS" OPTIMIZE ANY OF THE COMMON MANUAL OR AUTOMATED WELD PROCESSES ON ANY, ALL POSITION, CODE OR NONE CODE WELD APPLICATIONS. WHEN YOU CAN DO THIS, YOU ARE A WELD PROFESSIONAL. IF YOU CAN'T DO THIS, YOU ARE SIMPLY A WELDING OPERATOR..
MY RESOURCES SIMPLIFY YOUR PROCESS CONTROL AND BEST PRACTICE REQUIREMENTS
Below, Ed is providing MIG Best Practices - Process Control Training
for robot personnel at a USA company called Magna which is one of the world's largest auto - truck parts suppliers.
Ed training some of Magna's robot & manual weld personnel.
THE YOUNG, MAGNA ROBOT TECHNICIANS ED MET HAD GREAT CONFIDENCE IN THEIR ROBOT PROGRAMMING ABILITY, BUT THEIR MANAGEMENT HAD NOT PROVIDED THE TECHNICIANS WITH WELD PROCESS CONTROL AND BEST PRACTICE EXPERTISE.
I was requested to assist many Magna facilities, and in my visits came to the conclusion that the robot, MIG weld, process controls and best robot weld practices requirements was not well understood by the both their corporate or plant management that were involved in the robot weld decisions. As for the engineers and technicians that daily kept the robots working, the majority of the guys I met, knew plenty about robot programing but hardly knew anything on the subject of MIG weld best practices and MIG weld process controls.
The best thing that the engineering management at Magna did for their robot MIG lines, 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 forming ability to provide good parts for welding. When parts fit without serious weld gaps, robot welds become easier to achieve and robot technicians tend to get better weld results.
If you wish to use my highly effective robot MIG weld process control program to teach your self, or to train your employees CLICK HERE.
the left above, Ed is training American ship yard welders on how to reduce flux cored weld defects and optimize the flux cored and MIG welds without
"playing around" with their weld controls. In the middle, Ed shows Jesse, (age 11) that with less than 30 minutes of effective training, that it's a simple task to produce a code quality pipe root weld. By the way, thewelds were made on a
16 inch, Natural gas pipe supplied by Imperial Oil. On the right.
Ed training highly experienced Imperial Oil, SMAW pipe workers how to use and optimize their MIG
and flux cored welds for their field and shop pipe welds.
WITH ALL COMPANY WELD ISSUES: I FIRST LOOK TO THE MANAGEMENT, ENGINEERS AND SUPERVISORS AS THE ROOT CAUSE: