Weld Reality Home Page 2.
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WELD MANAGEMENT RARELY VISITS THIS WEB SITE, LETS FACE IT THEY ARE OFTEN TOO BUSY TRYING TO DOWSE THEIR WELD SHOP FIRES.
IF THEY DID VISIT THIS SITE THEY WOULD HAVE LESS CONCERNS FOR MANUAL & ROBOT, MIG & FLUX CORED, WELD QUALITY - PRODUCTIVITY - REWORK - REJECTS - RECALLS AND WELD LIABILITY ISSUES, THAT IS ONCE THEY AND THEIR SUPERVISORS AND TECHNICIANS BECOME FAMILER WITH THE WELD PROCESS CONTROLS & BEST WELD PRACTICES AVAILABLE AT THIS WEB SITE.
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WELD PROCESS CONTROLS - BEST WELD PRACTICE EXPERTISE IS READILY
SEEN WHEN COMPLEX AUTOMATED WELDS ARE REQUIRED.
Inconel or stainless weld clad area, 2 to 20.000 sq/feet. Ed's boiler wall clad MIG weld patent.
The welds shown are untouched, & the single MIG gun deposition rate was approx. 16 lb/hr.
In the 1990's, Ed developed the above USA - Europe "Pulsed MIG Overlay Clad Weld Patent". For this patent Ed created a unique pulsed program. One of the few applications that pulsed provides real world weld benefits is low dilution clad welds, especially when utilizing sluggish alloys. Ed's patent was was developed for WSI (Aquilex) Atlanta. This company uses approx. 1 million pounds of stainless / inconel and other alloy wires each year on clad applications. Ed's patent dramatically improved the cladd weld quality that globally is applied to Power Stations and Waste Energy Plants Water Wall Boilers and other components. Ed's patent also dramatically lowered the typical required costly Inconel / Stainless weld consumable costs by approx 25 - 30% per sq/ft. Another benefit for the power industry water wall industry, was the unique clad weld quality and low single pass weld dilution provided weld results that dramatically reduced the clad weld stresses, (increases boiler longevity). Click here for info.
Note: The Single Layer clad welds, would when tested have to indicate less than 7% dilution to acheive a single pass chrome content of > 20%. Ed's average single pass weld dilution was approx. 5%. His spatter free, "single MIG torch clad weld deposition rate achieved an average weld deposition rate of approx. 16 lb/hr.
AN INDICATION OF MIG WELD PROCESS CONTROL EXPERTISE IS EVIDENT WHEN ROBOT MIG WELDS WHICH IN REALITY ARE MADE BY DUMB - BLIND MACHINES CONSISTENTLY ATTAIN THE HIGHEST POSSIBLE MIG WELD QUALITY AND PRODUCTIVITY.. IMPOSSIBLE TO ATTAIN WITHOUT WELD PROCESS - CONTROLS AND BEST ROBOT WELD PRACTICE EXPERTISE. ED HAS ESTABLISED A HIGHLY EFFECTIVE 7 STEPS TO ROBOT WELD OPTIMIZATION PROGRAM.
INCREASING MIG DEPOSITION RATES ALLOWS FASTER WELD SPEEDS. INCREASING WELD SPEEDS WITH MIG IS ONE OF THE MOST LOGICAL METHODS TO REDUCE WELD HEAT AND DILUTION. THE MAJORITY OF ALL WELD APPLICATIONS, ESPECIALLY ALLOY WELDS, TYPICALLY BENEFIT FROM ATTAINING THE LOWEST POSSIBLE WELD HEAT. A PROCESS THAT ED BOUGHT TO NORTH AMERICA IS CALLED TIP TIG. THIS PROCESS PROVIDES THE HIGHEST POSSIBLE TIG WELD QUALITY WITH EN POLARITY IT THERFORE PROVIDES THE LOWEST POSSIBLE WELD HEAT.
2008: Automated or Manual welds. The capability of weld management, engineers and supervisor s in any industry is easily measured in their weld
process control - best weld practice evolution, and in their
accepatance of new weld
processes and weld
that actually provide real world weld / part benefits..
TIP TIG, THE WORLD'S MOST IMPORTANT WELD PROCESS, PITY THAT
FEW MANAGERS OR ENGINEERS HAVE BEEN AWARE OF IT.
It would take 6 to 8 regular TIG welders to produce the weld same production as the above two TIP TIG
welders, and with traditional TIG, they could not attain the same weld quality as attained with TIP TIG.
In a time when finding highly skilled TIG welders is difficult task for most managers, why would any manager have an interest in the TIP TIG process which dramatically lowere the welder skills and providess much higher weld manual / automated weld productivity and quality?
AERO SPACE, DEFENCE, NUCLEAR, POWER PLANT, OIL, GAS MEDICAL AND FOOD INDUSTRIES WAKE UP,
IT'S A SAD REFLECTION OF THE GENERAL LACK OF WELD ENGINEERING AND MANAGEMENT WELD PROCESS EXPERTISE, THAT IN THOSE HIGH TECH INDUSTRIES THAT PRODUCE CODE QUALITY AND ALLOYS WELDS, THAT AFTER ALMOST TWO DECADES SINCE IT'S INTRODUCTION, FEW WELD DECISION MAKERS ARE AWARE OF THE TIP TIG PROCESS.
THE HIGHLY EVOLVED GTAW (TIG) PROCESS IS CALLED TIP TIP. IN 2008 AS IT HAS BEEN FOR A DECADE, THIS PROCESS WAS BOUGHT TO NORTH AMERICA BY MYSELF AND BUISNESS PARTNER TOM O'MALLEY, I FOUND THIS BRILLIANT AUSTRIAN INVENTION AT MY FREIND'S DARREN MATHERSON LOCATION IN SCOTLAND.
PROVIDES NUMEROUS MANUAL - AUTOMATED WELD QUALITY - WELD COST BENEITS FOR NUMEROUS WELD APPLICATIONS. UNFORTUNAely IN AN INDUSTRY THAT IS GUIDED BY THE LOCAL WELD SALES ADVICE, IT MAY TAKE ANOTHER TWO DECADES BEFORE THE KEY WELD DECISION MAKERS IN THE HIGH TECH INDUSTRIES WAKE UP TO WELD REALITY OF TIIP TIG.
More info on TIP TIG in the TIP TIG program at this site.
1956 - 2016... A RARE ACHIEVEMENT
IN ANY GLOBAL
MIG - FLUX CORED WELDER EXPERIENCE, HAS LITTLE TO DO WITH WELD PROCESS CONTROLS - BEST WELD PRACTICE EXPERTISE.
2016: ONE THING ALL INDUSTRIES HAVE IN COMMON, MOST WELD MANAGERS AND SUPERVISORS HAVE FOR MORE THAN FOUR DECADES NOT FIGURED OUT THAT MIG - FLUX CORED "WELDER EXPERIENCE & WELDER SKILLS" HAS NOTHING TO DO WITH WELD PROCESS CONTROLS - BEST WELD PRACTICE KNOWLEGE:
WHILE MANY MANAGERS / ENGINEERS USE THE WORDS "BEST WELD PRACTICES" UNFORTUNATELY FEW WILL BE AWARE OF THE WELD PROCESS CONTROL EDUCATION REQUIRED TO IMPLEMENT MIG - FLUX CORED MANUAL OR ROBOT BEST WELD PRACTICES. ITS NOT ROCKET SCIENCE, AND OVER THE DECADES I HAVE CONTINUED TO SIMPLIFY MY PROCESS CONTROL, SELF TEACHING / TRAINING PROGRAMS. SO IF YOU HAVE 12 HRS TO LEARN MIG OR FLUX CORED WELD PROCESS CONTROLS - BEST WELD PRACTICES,
When I explain to management, engineers, supervisors and technicians that they and their weld personnel need Weld Process Control - Best Practice Training, a common response from many front office personnel is, "our guys don't need this as most of our welders have been with us for 20 years and they are highly skilled".
The managers and supervisors will often say this to me while we are watching their weld personnel grind away at poor welds and unnecessary weld spatter, or they may be watching their weld personnel play around with MIG or flux cored weld controls.
It's also never ceases to amaze me that when I do provide the Weld Process Control - Best Practice Training, that i have to insist that the front office weld decision makers and supervisors attend my one day class room, manual or robot, MIG - FCAW sessions. I guess as these personnel don't know what process weld process ownership and weld accountability means. Most dont understand the value of process training, and few understand that to consistently attain the best possible weld quality / productivity means all involved in the building walk the same weld control path.
You would not want to ask any so called experienced MIG welder with 10 + years experience to provide you with;
the wire feed/ amps/ travel speed and volt data that a robot will require to make a common 3/16
(5 mm) fillet weld with a 0.035 (1mm )wire.
 the MIG spray START POINT wire feed, amps and volt data for an 0.045 (1.2mm) wire and 80 - 20CO2.
You cannot implement manual / robot Best Weld Practices without weld process controls.
You cannot consistently attain the highest manual / robot weld quality with out process controls.
You cannot always attain the highest manual / robot weld production without process controls.
You cannot control weld costs, or figure out how to attain the lowest costs without process controls
You can never attain a robot's weld quality / productivity potential without weld process controls.
Consistent, optimum Manual and Robot weld quality / productivity is established through the primary weld decision maker's Best Weld Practices & Weld Process Controls Expertise. This is an expertise that for four dedades has been lacking at most global weld shops. This is an expertise that I have been developing and teaching for decades.
WELD EDUCATION FACILITIES . Process control expertise in 2016, is as far as I am aware still not taught or taught correctly at any global University, College or training facility that teaches Weld or Mechanical Engineers or Weld Technicians. Since the nineteen nineties, my weld Process Controls - Best Weld Practices self teaching - training programs have been available at this web site.
Best Weld Practices - Weld Process Control Resources.
|You don't get asked to improve the welds on USA ICONIC consumer products, unless you have weld process control - best practice expertise.
Above, a few of the robot MIG applications that Ed optimized.
WHEN INVITED TO ANY GLOBAL MFG. PLANT, IT TYPICALLY WOULD TAKE ME 1 TO 2 DAYS TO OPTIMIZE ANY MANUAL OR ROBOT WELDS AND PRODUCE THE RESOLUTIONS NECESSARY TO ANY OF THE PLANTS WELD QUALITY - PRODUCTIVITY ISSUES. IT WOULD THEN TAKE ANOTHER DAY TO PROVIDE THE PROCESS CONTROL TRAINING, AND I WOULD ENSURE THAT ALL THE RELEVANT FRONT OFFICE PERSONEL WERE INCLUDED..
A FEW OF MY "ROBOT" WELD OPTIMIZATION APPLICATIONS INCLUDE.....
Harley Bike Frames- GM Corvette Bodies and numerous parts - Volvo - Case Truck Cabs and numerous parts- Ford F150 Trucks and Numerous Parts- VW Beetle Seats - Numerous applications for Chrysler - Subaru
- Volkswagen - Mercedes - Honda - GE - ABB - Westinghouse - Babcock - Textron Armor Tanks-
General Dynamics - Imperial Oil (pipes)- Combustion Engineering - Hydro Aluminum - Hayes
Lemmerz Wheels - Fruehauf Trailers - Case - Club Car - Genie - Sky Track - Manatowic
- John Deere - Caterpillar - Johnson Controls - DANA - Tower - Flow Master and Monroe Shocks.
IT DOES NOT MATTER IF YOU RESPONSIBLE FOR BUILDING TRUCKS, OIL PATFORMS OR SUBMARINES, AS A MANAGER, ENGINEER OR SUPERVISOR YOU DESERVE TO LOOSE SLEEP IF YOU DO NOT HAVE WELD PROCESS CONTROL EXPERISE AND CAN APPLY BEST WELD PRACTICES, TWO FUNDAMENTAL NECESSARY TO REDUCE YOUR COMPANIES WELD LIABILTY POTENTIAL.
With the common weld processes such as MIG, Flux Cored and GTAW, and the ever increasing, extraordinary amount of poor and inconsistent weld quality that is produced daily around the globe, the
potential for catastrophic weld failures and costly product liability issues dramatically increases each year.
Small weld issues have often creates grave consequences.
A few bad welds on a large weld application
could cost many lifes
and create liability costs over a billion dollars.
2013: $$$ REJECTS - $$$ REWORK - $$$$ GRINDING - $$$ POOR PRODUCTIVITY:
the industries that utilize the MIG and flux cored weld processes, thanks to engineering apathy and lack of weld management ownership, hundreds
of millions of dollars are daily spent on;
 unnecessary weld rework,
 unnecessary NDT costs,
unnecessary weld rejects,
unnecessary weld rework,
unnecessary weld cleaning,
 unnecessary weld meeting
and then add to this the typical poor or inconsistent weld productivity and you figure out the importance of process control expertise.
Weld Process Controls - Best Practices
is essential to control & minimize weld costs.
SIMPLE WELD COST QUESTION... A MIG or flux cored welder using an 0.045 (1.2 mm) solid or gas shielded flux cored wire wire, works in a weld cell for 8 hours a day. The welder has nothing to do all day but weld pre-tacked parts in the flat weld position. The welds are all 1/4 (6 mm) fillet welds. The welders average arc on time each hour is 30 minutes. In a plant that knows the correct MI - FCAW settings, how much weld wire on average would the welder use each shift? If it takes you more than 3 minutes to figure this out, you will benefit greatly from any one of my process control self teaching programs..
THE USE OF A GRINDER ON MIG WELDS IN A WELL MANAGED WELD SHOP, SHOULD BE AS RARE AS HEARING AN INTELLIGENT COMMENT FROM DONALD TRUMP.
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. A section I eventually stopped writing as the evidence was simply over whelming.
You may also want to take a few moments to read about about the extremely poor Self Shielded (SS) flux wire welds that were responsible for millions of dollars spent annually on unnecessary Chrysler robot weld rework. The poor Chrysler welds were caused by the poor weld wire recommendation from the corporate Chrysler weld engineer who got his weld advice from a Lincoln salesman . And just to show what a real problem we have with poor sales advice in North America, you may also want to read why similar Self Shielded wires were used on CA construction projects that were built over earth quake fault lines.
Many of the buildings
and bridges that toppled during an earth tremor in North Ridge, California, were welded with Self Shielded Wires and guess where the primary support structures broke. By the way the
Chrysler Corporation and the engineering idiots in CA and at FEMA are still many years later still recommending the sad Self Shielded process.
Management & the Self Shielded Flux Cored Weld Fiasco.
Many of the North Ridge, California structures that collapsed (above), were supposed to be designed to stand up to the anticipated CA seismic quake loads, yet with a few tremors well within the seismic design load criteria, these buildings and many other structures collapsed like a pack of cards. The bottom line with North Ridge, when you cut through all the corporate, design, engineering and political lack of accountability, and weld process ignorance, many of the buildings simply collapsed due to "weld failures" with SS weld wires made by "unsuitable Lincoln, Self Shielded (SS) flux cored wires".
(Note: Hobart also makes similar consumables)
It should makes any rational person shake their head at the gross weld process ignorance and ineptitude shown in CA. And to make things worse. the world's most inept government organization, FEMA then became involved in making weld spec requirements for construction
projects. This is the FEMA that could not make trailers suitable for Hurricane Katrina victims. Of course FEMA with its none weld back ground and no weld process expertise sees no problem becoming involved in weld specification and recommending the SS wires which are still in use in 2016...
|2000: The Oil - Nat Gas industry is an industry in which the front office managers, engineers and supervisors
responsible for welds, will too frequently be weld decision makers who will lack MIG - Flux Cored weld process control - best weld practice expertise. It's more likely in these industries to find front office weld decision makers stuck in the; "This is the way we have always done it" engineering mode..
WHEN IT COMES TO CONSTRUCTION & REPAIR WELD PROJECTS, FOR DECADES, MOST NORTH AMERICAN REFINERY MANAGERS & ENGINEERS HAVE BEEN STUCK IN A WELD TWILIGHT ZONE.
year was 1984. I was asked to consult on some serious pipe weld issues at one of the largest oil refineries in Houston TX. At the refinery, a new section
was about to be added. The pipe project required over a thousand pipe welds and I recommended TIG roots and 0.045 gas shielded flux cored fill passes.
Those responsible for the weld decisions were in the usual "why change the way we have always done it crowd? after all the refinery was built sucessfully with the Stick weld process back in the 1950s. In the 1980s as you would have found as you will find today in 2016, the refinery engineering and management weld decision makers, too often want to stay in their weld comfort zones, and use the traditional SMAW (stick) or TIG for the pipe
fill pass welds. The engineers and managers weld process ignorance and apathy about the use of the gas shielded flux cored process for the fill passes was very costly for this refinery. I figured out that the use of the gas shielded flux cored wires which would have created far superior weld quality (less weld rewor) with weld labor cost savings of approx. two million dollars.
IN THE WELD SHOPS THAT TYPICALLY PRODUCE PIPE / PRESSURE VESSEL WELDS ON CODE QUALITY APPLICATIONS, YOU WILL OFTEN HEAR
MANY MIG AND FLUX CORED WELD
YET FEW OF THE OPINIONS WILL BE BASED ON WELD REALITY:
In the weld report I presented to the senior management at the refinery, I included the following in my report: "On the subject of the best weld process choice for your
new refinery extension, during the weld meetings that I attended
with your contractors, project managers and engineers, I hope you are aware that the personnel that were the most vocal against the utilization of the highly
cost effective Gas Shielded Flux Cored process, indicated to me that they were the least qualified in the meetings to have an opinion on any weld process".
Many of the good old boys rarely like
Give them a 6010 or 7018 electrode and they will build you a refinerary in 2016 much the same as it was origionally built in 1956.
I don't suppose you ever heard in your weld - fab shop,
"WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT"
Management and the increased Weld Liabilty Consequences that
is derived from the common front office
Lack of Weld Process / Control Expertise.
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 fully understand the important equipment and processes utilized daily?
Wheres the stick electrodes?
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 TIP TIG processes that would enable dramatic quality improvements with much lower weld labor costs.
Note: TIP TIG is the evolved GTAW (TIG) process. TIP TIG as either a semi-automatic manual or automated process will in contrast to manual TIG, or automated Cold / Hot Wire TIG, provide many unique weld quality, productivity and metallurgical weld benefits.TIP TIG was invented in Austria by Plasch. I created the TIP TIG USA company and then bought this important process to both N. America and Australia. More info visit ww.tiptigusa.com.
DOW CHEMICAL MANAGEMENT FOR
THE LAST THREE DECADES
|2016: When it comes to the welds produced in the last decade, there are many large Fortune 500 companies that like DOW have been stuck in a 1960's welding Twi-light zone.
2007: IT WAS EVIDENT THAT FOR DECADES THERE WAS A LACK OF CORPORATE MANAGEMENT AND ENGINEERING WELD PROCESS OWNERSHIP AND EXPERTISE AT A GLOBAL COMPANY THAT SHOULD HAVE KNOWN BETTER. THE COMPANY WAS CALLED DOW CHEMICAL:
I had just visited a plant in which Dow Chemical, one of the USA largest chemical companies had requested that a 304
stainless vessel approx. 3 inch thick and 8 feet in diameter, was to be welded with 1/8
(3.2 mm) diameter STICK electrodes.
Remember I have been in hundreds of plants and involved in thousands of weld applications and over the years, the "this is the way we did it in the 1950s" is a pathetic approach to large weld applications in which for decades there has een are more viable process choices. The "why change" approach in the engineering department is something I had seen many times with DOW weld applications. What is ironic is this will come as a surprise to many of the DOW senior engineers and managers who would not know a good weld if they tripped over it.
FOR DECADES, WHEN IT WAS NOT NECESSARY, with many of their large scale weld applications, the Dow managers / engineers would insist on the utilization
of SMAW (stick) or the very slow GTAW process. These engineers were simply not comfortable or not aware of what they could have attained with either the MIG - Flux Cored or TiP TiG weld processes.
LACK OF PROCESS EXPERTISE ALWAYS HAS A PRICE....For decades many of the DOW senior managers and engineers have on their large construction projects, dramatically increased
their companies weld construction costs and reduced the projects weld quality potential.
THE BOTTOM LINE, WHEN RESPONSIBLE MANAGERS AND SUPERVISORS ARE NOT AWARE OF THE BENEFITS OF WELD PROCESS CONTROLS AND THE REQUIRED EXPERTISE OF WELD PROCESS CONTROLS / BEST WELD PRACTICES ON THE APPLICATIONS THAT THEY MANAGE, THEY ARE LIKELY TO INSIST THAT THE APPLICATION BE WELDED THE WAY IT WAS WHEN IT WAS FIRST BUILT A FEW DECADES AGO.
THE UNNECESSARY GLOBAL MANAGEMENT CONCERN, FOR FINDING SKILLED MIG - FLUX CORED - TIG WELD PERSONNEL:
PICK UP A WELD MAGAZINE OR READ THE BUISNESS SECTION AND BEFORE LONG YOU WILL READ 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 4 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
IN WORLD WAR TWO, WITHIN A FEW DAYS, THE WOMEN TOOK OVER MANY OF THE MEN'S JOBS, THEY QUICKLY REVEALED A FEW
FACTS ABOUT THOSE EXPERIENCED WELDER SKILLS:
Universities - Colleges - Trade Schools and Weld Training facilities
don't typically teach manual - robot MIG - FCAW process controls - best practices, however I developed these programs over 30 years, and they are available at
for the price of a good meal for 4.
Left above. Ed training ship yard welders at Aker, located in the Navy Yard Philadelphia. The training was focussed on how to reduce flux cored weld defects and how to optimize the weld quality and productivity without
"playing around" with the weld controls.
Middle. Ed providing MIG and flux cored pipe weld training for Imperial Oil pipe welders. Application 16 inch, Natural gas pipe. On right while the pipe welders had a break, Ed then trained his buddy Jesse, (age 11) that with less than an hour of "effective process training", it's an easy task for an 11 year old to produce all position, code quality pipe MIG root welds, and flux cored fill pass welds.
WHEN I AM INVITED TO EXAMINE A COMPANIE'S WELD ISSUES, I FIRST EXAMINE THE EXPERTISE OF THE RESPONSIBLE MANAGEMENT, ENGINEERS AND SUPERVISORS... OCCASIONALY IT'S LACKING...