Rev. Aug 2017..
More on MIG - Flux Cored Weld Process
Controls & Best Practices:
What you will find in this section.
Lawyers may want to read this section to find out how inconsistent, poor MIG and Resistance weld quality affects vehicle crashes, offering great financial opportunities.
Item: Why this Volvo truck part, automated weld quality and productivity could not be achieved with this under qualified Volvo manager
Item: The fear of weld process change is natural at those plants in which the management and engineers responsible, are not in control of the weld equipment and processes they own.
Item: In contrast to most fab shops, the ratio of engineers to shop floor workers is very high in the auto - truck industry. Yet in this vehicle industry weld best practices and the weld process controls necessary for automated weld quality - productivity optimization are typically rare or none exist ant.
Item: Many plant or manufacturing managers will often
not report the real robot weld
quality and productivity costs to their corporate peers.
Item: There are hazards and restrictions when building vehicles that are designed by engineers who would not
know a good weld if it was four inches from their nose.
Item: Why Americans should give consideration the the welds before they drive
across that next steel bridge.
Item: The world's largest auto - truck wheel manufacturer produced poor and inconsistent quality mechanized welds and their apathetic, inexperienced management helped drive them out of business.
Item: Is it logical to want those that are paid to daily make manufacturing process decisions to understand the scope, accountability and responsibility of their profession?
Item: Why would this Volvo plant manager want to hire skilled welders to run his MIG welding robots, when skills have little to do with attaining optimum robot weld quality and productivity.
Item: Why did GM senior management waste nearly a million dollars when welding the Corvette?
WHEN AN INDUSTRY STRUGGLES FOR MORE THAN SIX DECADES WITH TWO SIMPLE CONTROLS ON IT'S PRIMARY PROCESS EQUIPMENT (MIG), IT' SHOULD BE NO SURPRISE THAT WELD PERSONNEL "PLAYING AROUND" WITH THEIR WELD CONTROLS IS NOT ACCEPTABLE:
THE BAD NEWS. For decades the weld industry has not focused on the required Weld Process Control Expertise and the Best Weld Practices required for the two most widely used weld processes, MIG - Flux Cored. With this in mind it's logical to assume that there will be large scale weld quality, weld cost consequences.
THE GOOD NEWS for the majority of global weld shops is, typically one does not have to look far to find a great opportunity to produce substantial weld quality improvements and enable dramatic weld cost savings.
Without MIG - FCA weld process control expertise, it's not an easy task to create major changes in an industry in which many of the managers, supervisors, engineers and technicians have for decades relied on weld 'salesman' for weld advice.
Without MIG - FCA weld process control expertise, it's not easy
task to deal with the common, numerous global weld shop process myths, the often incorrect weld practices, and the extensive erroneous weld information that prevails in the many weld shops in which so called experienced weld personel are 'playing around" with two simple weld controls" .
In the above environments, it's not logical to believe that the weld shop floor personnel are going to be the ones to drive effective weld quality - productivity improvements. The necessary changes for both manual / robot MIG - FCA process optimization, which by the way with the right resources is easy to implement should of course be driven by those that are responsible for the weld shop personnel and responsible for the daily weld quality, productivity and costs.
2000 PLEASE NOTE: THIS WEB SITE ESTABLISHED BY ED CRAIG IN THE 1990s HAS ALWAYS FOCUSSED ON THE COMMON, GLOBAL, ROOT CAUSES OF MANUAL &ROBOT MIG AND FLUX CORED WELD ISSUES.
I BELIEVE THIS SITE CAN BE AN IMPORTANT CATALYST FOR THOSE WELD DECISION MAKERS THAT WANT TO IMPLEMENT THE PROCESS CHANGES REQUIRED IN MOST WELD SHOPS. ALSO PLEASE BE AWARE THAT MY 'CONSTRUCTIVE CRITICISM" IS NECESSARY IN AN INDUSTRY INWHICH FOR DECADES MAJOR CHANGES HAVE BEEN NECESSARY.
FOR WELD MANAGERS, ENGINEERS AND SUPERVISORS, THIS SITE CAN PROVIDE YOU WITH MANY PRACTICAL, COST EFFECTIVE WELD QUALITY - PRODUCTIVITY RESOLUTIONS, AND ALSO WITH THE PROCESS CONTROL - BEST PRACTICE TRAINING RESOURCES THAT WILL HELP YOU OR YOUR ORGANIZATION ATTAIN THE HIGHEST POSSIBLE MIG - FCA MANUAL - ROBOT WELD QUALITY, ALWAYS AT THE LOWEST POSSIBLE WELD COSTS...
It may come as a shock for those plants weld mostly steel and alloy steel applications, and invested in costly, (poor duablity - expensive to repair), pulsed MIG equipment, to find out that for approx. three decades that Ive been evaluating this equip, that the PULSED MIG weld equipment electronic BELLS & WHISTLES have provided minimal weld quality and productivity benefits for most steel - alloy stl welds, however these electronic features have for decades enabled greatly increased prices and profits for both the MIG weld
equipment manufacturers and distributors.
Thanks to the GLOBAL lack of MIG - FCA weld process control - best practice expertise, in the past three decades, the majority of weld shops have thrown money out of their windows on the purchase of unecessary, costly, gas mixes and cored consumables that are not required, and also on pulsed MIG weld equipment that for most steel / alloy steel applications has typically been loaded with useless, electronic bells and whistles.
I would like to know another industry that for decades has relied heavily on biased,
unqualified sales influence to help resolve it's day to day technical, weld quality, productivity and weld cost issues...
For the last three decades, throughout the global MIG weld industry, millions of weld shops have paid 100 to 400% more than necessary to purchase a pulsed MIG power source. In the same shops they may also decide to waste more of their hard earned dollars by paying 2 - 60% more for useless three part gas mixes, or pay premium prices for unnecessary metal cored or flux cored wires. The solution to this unnecessary waste is simple. When the key weld decision makers in a weld shop have weld process control - best practice expertise, that expertise will be able to cut through the global weld equipment - consumables sales induced BS.
With weld process control expertise, the weld decision maker will have the important ability to provide the practical, cost effective requirements that are necessary to daily attain consistent, optimum weld quality and productivity,
and of course always at the lowest possible costs.
It's ironic, that in contrast to to the lower cost, traditional, CV MIG equipment, pulsed MIG equipment, multi-purpose MIG equipment, and MIG Inverters have for two decades typically provided inferior MIG and Flux Cored weld fusion profiles, higher weld porosity content and lower deposition rates for the majority of common carbon steels and alloy steels applications > 4 mm. The reason for these issues can are found at this web site and in
the MIG equipment sections, and of course in my weld process controls, best practices training resources.
The fear of a weld process or weld consumable change is natural on most weld shop floors,
and the fear will be exasperated when the relevant management, engineers, supervisors and technicians are not in full control of their weld equipment, processes and consumables.
The above infamous, common, weld shop refrain, should not happen
weld personnel who fully understand the processes they operate.
To resolve those common, daily weld shop
issues, will of course require "CHANGE".
It's not just "millions of welders daily playing around with MIG weld controls that is a primary concern for most weld shops,
it's also the hands off, management and supervision, and their reliance on sales biased weld process advice that is a concern.
This web site has a primary, repeating theme which is, "weld process control and best weld practice ignorance and apathy has influenced and created a common global weld shop culture, and that culture rarely likes to change the way it welds. In this environment, there is in many global weld plants, great opportunities for both weld quality improvements and dramatic weld cost savings.
How's your Weld Ownership - Weld Accountablity - Weld Expertise?
Imagine presenting the following
weld shop business plan to a bank manager.
Management and Weld Consumables: Many weld shops in the 1980's were primarily utilizing the poor quality, poor productivity SMAW (stick) process instead of the more cost effective MIG and flux cored weld processes, and its a sad reflection that 30 years later in 2014, you can make that same statement. Also in 2014, many companies are using costly metal or flux cored wires instead of utilizing lower cost MIG wires.
Many weld fab shops, construction projects and companies that employ engineers that should know better such as the Chrysler Corporation, encourage the use of the obnoxious Self Shielded, (SS) Flux Cored weld wires. Apart from poisoning their employees with the carcinogenic, SS flux cored weld fumes, someone should point out to the ignorant management and engineers that allow the use of these flux cored wires, that when the SS process is used, it's almost impossible to consistently, enable optimum weld quality, or produce cost effective weld production on any weld application.
Weld Equipment Bells and Whistles: The
majority of electronics in today's MIG equipment offer limited real world weld quality or productivity
benefits when welding the common steel and alloy steels applications. However these MIG equipment electronics have on
average increased weld equipment costs by 100 to 600%, reduced the equipment durability and longevity and increased weld equipment
repair costs by at least 100 to 500%.
MIG Gas Mixes and Weld Consumables:There
are approx. 60 global MIG gas mixes available for MIG welding the common steels, stainless
and aluminium applications, yet the weld world needs only 4 gas mixes for optimum MIG welds
on every weld application.
How many managers this year know what the best four MIG gas mixes are? (Info in my MIG gas mix section). Also how many managers, engineers and supervisors will while looking for a solution to their daily weld shop issues. with advice from their local weld sales rep, try a more costly flux cored weld consumable?
Management and their Bigger Weld Wire is Better nonsense: There are many weld process ignorant managers, especially in the auto - truck industry, that believes that the bigger the weld wire utilized, the greater the the weld deposition and the lower the weld costs. As the weld current required for the large weld wires is typically not suited to the welds and the part thickness, that bigger is better weld wire is simply another old worn out weld myth. Its a sad weld reality that the majority of global weld shops have for decades been using the wrong type, the wrong size of MIG and flux cored weld wires, which goes along with the fact that they are frequently using the wrong weld gas mix.
Equipment - Process Ownership - Accountability & Expertise.
In my 50 years in this weld business, I have
yet to meet two guys like these.
|If most managers, engineers and supervisors ran a weld shop
as if they had money invested in that shop, perhaps things
would be different.
This company spent millions on robots and
fixtures and made these welds on Ford Truck frames.