TIP TIG Welding is always better quality than TIG and 100 to 500% faster with superior quality than TIG - MIG - FCAW.

Weld Reality Home

Ed's Flux cored Book and training resources information

Flux Cored Weld Test

Flux Cored & MIG. All Position Welds.

The pipe welding industry. Often apathy,
lots of attitude with little weld process evolution.

FLUX CORED AND MIG. PIPE WELDING AND PROCESS MYTHS:

2009: SLOW WELD PROCESS EVOLUTION:

It's amazing in 2009, that 30 plus years after the introduction of gas shielded flux cored wires, the number of global weld shops especially in the construction, oil and power industries that still insist on using the low weld deposition traditional TIG or stick (SMAW) processes.

In the pipe industry the evolution of both the flux cored and MIG processes has been painfully slow, especially in industries where unqualified weld management and mechanical, electrical engineers or project managers lack MIG or FLUX CORED weld process expertise and confidence. The global lack of weld process control expertise is a sad state of affairs, especially when all it takes, is for the weld decision maker to read a process control book on this subject.

As we head in to 2010, I hope the new welding generation will quickly evaluate and embrace the world's best, manual pipe welding process which was introduced into North Ameica through this site. When you have a moment please take a look at the TIP TIG weld process.


QA and PROCESS ISSUES: E-mail Question: Sept. 2007:


Hi Ed. My AWS approved weld inspector was working with a new application using 316 stainless flux cored wires. We had not used this weld wire before, so he set up a weld qualification test. The weld inspector ran the procedure with the 316 flux cored wire and a helium tri mix containing 90% He / 7.5% Ar / 2.5%CO2 . The welds look cold, and when we sectioned the welds, we found lack of fusion, porosity and slag inclusions. The inspector told me that he got the gas info from AWS and they said the tri mix could be used for this. I think he's made a mistake. I have never heard or seen where the tri mix can be used for flux cored. Ed, do you know if the welds can pass mechanical test requirements with this helium tri mix.

Ed's Answer: It's hard to believe that 30 years after the introduction of steel and stainless flux cored consumables, weld wires by the way that have only ever used 3 shielding gas mixes, argon 20-25% CO2 and straight CO2, that someone who received training from the AWS and has a responsible role in a weld shop would try to qualify stainless flux cored welds with a helium tri mix.

With the highly inert tri-gas mix, you will have extensive lack of weld fusion, extensive porosity and slag entrapment. You will also create welds that exceed their maximum strength and have lost ductility. I don't believe anyone at the AWS gave him weld advice, as giving weld advice is not a common American Weld Society function. This guy's role in this costly endeavor does not say much for the value of him or his AWS certification. I would recommend this guy gets some real weld process education and you know where to find that...

IF WE CAN BRING CHANGE TO WASHINGTON, SURELY
MANAGERS CAN BRING CHANGE TO GLOBAL WELD SHOPS:

In the world where numerous managers, supervisors don't question why welders “play around”with their MIG or flux cored weld controls, it’s not hard to understand why weld issues are so common and weld costs are poorly understood.

Tremendous weld cost reduction potential will always be found in
ship yards, construction projects, refineries, oil platforms
and of course the infamous auto / truck plants:

YOU WOULD THINK THAT IN THE INDUSTRIES THAT DO THE MOST WELDS, THAT THERE WOULD BE THE GREATEST FOCUS ON WELD QUALITY AND WELD COST CONTROLS.

[] WELD COST FACT: NO ONE USES MORE FLUX CORED WIRE THAN A SHIP YARD.

[] WELD COST FACT: NO ONE HAS GREATER WELD REPAIR COSTS THAN A SHIP YARD.


2005: THE WELD REALITY: WITH WELD REWORK COST PER-SHIP FREQUENTLY MEASURED IN THE MILLIONS OF DOLLARS, LESS THAN FIVE PERCENT OF GLOBAL SHIP YARDS HAVE ESTABLISHED BEST MIG / FLUX CORED WELD PRACTICES AND PROVIDED THEIR EMPLOYEES WITH MIG AND FLUX CORED WELD PROCESS CONTROL TRAINING: PLEASE NOT, SKILLS TRAINING, IS NOT PROCESS CONTROL TRAINING.


TAKE A LOOK AT THE MULTI-MILLION DOLLAR COST SAVINGS ONE USA SHIP YARD ATTAINED, USING ED'S UNIQUE MIG AND FLUX CORED BEST WELD PRACTICES / PROCESS TRAINING PROGRAMS.

During the first four months of 2007, I presented a manual flux cored weld process control training program to Aker Kvaerner, an international ship Builder, located at the the Philadelphia Naval Ship Yard.

The 300 plus welders in the yard used E71T-1 (1.2 mm) flux cored wires to weld all position, vee groove, 12 to 25mm, steel joints with ceramic backing. Like most ship yards, the Aker weld training focus was on stick welding and particular attention would be focussed on the "welder's skills". Of course like any ship yard, all the welders had to pass the all position, flux cored weld qualification tests and it was commom to find welds as shown on the right.

The weld qualification test and weld procedures utililized at the yard had little in common with the real world weld requirements and weld application variables found in the yard.

It's commom in many large fabrication facilities to find a general lack of both MIG and flux cored weld process control expertise. Its also too common in ship yards to find that many of the weld personnel lack an awareness of the unique flux cored weld process control requirements necessy for all position vee groove, ceramic backed welds.



After establishing the ground work for uniform Best Weld Practices with the weld equipment and consumables, all the welders and supervisors in the yard participated in one of Ed's unique Weld Process Control Training Programs.

The training program focussed on the flux cored Weld and Consumable Process Control requirements, and the unique optimum weld process techniques for all position, vee groove welds with ceramic backing. In a time of welder shortage, when many companies find it difficult to interrupt their daily productivity, management take note. Ed's easy to present process training program requires only eight hours, four hours classroom and four hours hands on. In a few weeks the training for the 300 plus welders was complete and the ship yard QA department started to analyze the results..

Three months after Ed's process control the training, the ship yard's quality control management indicated a 50 - 60 % reduction in the required weld rework per-ship. The ship yard reported that the reduced weld rework, labor and NDT costs, would result in a cost savings of approx. 4.5 million dollars per-ship.

THE COST BENEFITS FROM HIGH IMPACT, ONE DAY, CUSTOM TRAINING: Examine the real world ship yard weld cost reduction and benefits for Ed's unique training program that is so simple you dont need weld expertise to present it. The training program required 300 x 8 man/hr. = 2400 man hours at an approx. $30/hr, = base labor cost for the ship yard of $72,000. for the training. To this add the actual training costs of approx. $100,000 = for a total training costs of approx. $172,000.

Savings, four plus million dollars per-ship and training costs approx. $172,000. An unreported fact from this yard was the changes that Ed established in the new weld procedure wire feed settings. The increased flux cored wire feed rates, (weld deposition rates) increased the daily weld productivity per-man in a range from 20 to 40%.


Some of you may wonderwhat's the difference between this type of weld training program and the MIG and flux cored weld training you could expect in any North American, Korean, Chinese, Japanese, European ship yard or any manufacturing facility?

For decades conventional training in ship yards or manufacturing plants has focussed on the welders skills, especially stick welding skills which have nothing in common with MIG or flux cored. It's not unusual for weld personnel to have weeks of hands on training at the ship yards and then find they still;

[a] play with the MIG weld equipment controls,
[b] utilize the weld controls in a very limited manner,
[c] do not utilize optimum weld techniques for the MIG and flux cored process.

This of course limits the daily weld quality and productivity potential the welders could achieve.

The process training I provide, as with all my training programs, enables each individual to achieve Flux cored welding process optimization for the consumables and for the all position, vee groove, ceramic backed or open root applications. For the welder who took the eight 8 hour process control training, the program enabled that individual the ability to instantly set optimum parameters for the consumable, and weld joint variables provided instant dramatic improvements in their weld ability.

As you can see, on the left picture we have a weld made by an individual with poor skills, poor techniques and poor gas shielded (CO2) flux cored weld settings. These two vertical up, vee groove, weld samples using flux cored wires and CO2, were made by the same welder in an eight hour period. On the left before and on the right after the eight hours of process control training.

Even when the welder had good skills, this type of training will increase the welders weld quality and productivity capability. What was also important, was each welder became aware of the unique flux cored weld parameters and technique requirements necessary to address the variable root gaps over the ceramic. With all weld personnel process control training will ensure weld productivity will typically be increased in the 20 to 40% range and their will be an instant reduction in lack of weld fusion, slag entrapment and porosity defects.

The improvements by all the welders was immediately noticed by the ship yard QA management who measured the dramatic improvements evident through NDT and radiographs. The bottom line was of course the dramatic four plus million dollars cost reduction that Aker generatted from the reduction in the required daily weld rework.


Aker gained 4 million dollars fron a weld training cost of $170.000. By the way, few global ship yards or manufacturing facilities examine the cost effectiveness of the training programs they develop.

For example, instead of an eight hour training program, if the ship yard was to provide a forty hour welder training program for 300 welders in any North American facility, and the minimal labor training and associated costs will be approx. $500,000. Plus the facility will have lost 12000 production hours.


Special thanks to Tom O'Malley the owner of Excell. Tom's company is the prime weld products supplier to the Philadelphia Naval Ship yard. Tom provided the facilities and equipment for the weld training. Tom also assisted Ed with the program in both the classroom and hands on training. Tom is one of those rare owners of a weld supply company that actually spends many hours per-week evaluating weld processes equipment and consumables.

If you are teaching your self, or providing weld process control training for others, the following weld resources are the key to attaining MIG and flux cored weld process optimization. Item.1. The Book: "A Management & Engineers Guide To MIG Weld Quality, Productivity & Costs" Item 2.A unique robot MIG training or self teaching resource. "Optimum Robot MIG Welds from Weld Process Controls". Item 3.A unique MIG training or self teaching resource. " Manual MIG Weld Process Optimization from Weld Process Controls". Item. 4. A unique flux cored training or self teaching resource. "Optimum Manual and Automated Flux Cored Plate and Pipe welds. Item 5a."Proceso de Soldadura MIG Manual" (MIG Made Simple. Self teaching in Spanish) Item 6a.The Self Teaching MIG Book/ Video. (MIG Made Simple in English). Visit Ed's MIG / flux cored process control books and CD training resources.

 

There is always a place for SMAW welding, but from a weld quality and productivity and cost perspective,it needs to be a limited place.

IF YOU HAVE NO SENSE OF HUMOR YOU SHOULD
NOT BE AT THIS SITE OR IN THE WELDING INDUSTRY

 

ED'S PIPE WELDING ROBOT:

WITHOUT QUESTION, A SIX AXIS ROBOT HAS ALWAYS BEEN ONE
OF THE MOST VERSATILE TOOLS THAT COULD BE USED FOR
AUTOMATED PIPE WELDING TECHNIQUES.

.

During 1997, I set this robot To weld a 48 inch pipe. I used an ABB robot and used short circuit transfer for the vertical down root. The robot pipe fill pass welds were made in the vertical up position using an 0.052 Alloy Rod Dual Shield E71T-1 wire with 80% Argon - 20% C02. The vertical up flux cord weld, produced a weld deposition rate of approx. "ten pounds an hour"

The high flux cored weld deposition rate, combined with the fast robot movement between welds, (faster than any other available automated pipe weld equipment) provides greater pipe line weld production potential than any other available automated pipe weld unit.

In 2009 there is still no automated, mechanized pipe line weld unit available that can offer the flexibility or weld process communication of a six axis robot for welding pipe bevels. A robot provides many unique features for pipe welds.

[a] accurate, flexible through the arc weld joint tracking,
[b] adaptive controls that can compensate for different welding conditions,
[c] super fast speeds between welds,
[d] superior communication with the welding power source. Combined these features offer the world's greatest automated pipe welder.

Just imagine, one day we may then see two small robots hanging down, mounted on a "ROBO RIG" truck, that traverses that Texas, Canadian or Middle East pipe line.

 

 

ED'S 1997 "ROBO RIG", PATIENTLY WAITING
FOR A SLEEPY INDUSTRY TO RECOGNIZE OPPORTUNITY:

ED'S 1997 WELD SHOP OR FIELD ROBO RIG: Two automated pipe welding carriages welding with MIG and flux cored wires, attached to two sophisticated electronic power sources can cost over $150,000. In contrast, two robots attached to two power sources could cost approx. $100,000. The pipe welding robots could be mounted on a portable tractor driven gantry for field pipe welding techniques.

[] Robo Rig: With two pipe welding robots hanging upside down, you have a mechanized unit that offers automatic touch joint sensing, through the arc impedance joint tracking, adaptive weld controls that will compensate for pipe joint deviations. For the pipe shop, simply present the pipe to the gantry and tell the robot the required weld schedule to use. For that pipe line, drive the Robo Rig to the weld joint. In less than 10 seconds, the robots or robot will locate the pipe bevel and pipe root, in contrast setting track for two less flexible, two axis mechanized carriages can easily take 20 to 30 minutes.

[] The Robot Rig will dramatically reduce the total pipe weld time. At the end of a fill pass weld, a robot can be in place to weld the next fill pass within 3 seconds.

[] The Robo Rig will have a flexibility that far surpass any automated pipe welding carriage. This flexibility will optimize the robot weld gun positions for the all position pipe welds. The robot can automatically sense a weld direction or side wall dimension change and instantly provide weld speed, weld direction and process changes to compensate.

[] The robot can change tools in seconds, one minute it's welding the next minute it's cleaning the slag from the welds.

[] The Robo Rig will have far superior communication and will store as many weld schedules as you will ever require.

 

 

WHEN IT COMES TO MIG OR FLUX CORED PIPE WELD ISSUES IN THE CHEMICAL, OIL AND POWER INDUSTRIES, WELD PROCESS EXPERTISE WILL ALWAYS HAVE A GREATER IMPACT ON A PROJECT THAN THE WELDING DOLLARS SPENT ON COSTLY, SOPHISTICATED ELECTRONIC WELD EQUIPMENT.

High Speed Pipe Preheat. Depending on the pipe, it's typically necessary to preheat the pipe ends within a very short period of time. The new Inductance equipement installed on the Vietz ARCOTRAC welding tractor has been designed to reach 300o C within approx. 60 seconds.

Someones doing it right. With an updated automatic pipe-welding system, J. Ray McDermott Inc. (Houston, TX) continues to help set world production records for laying oil and natural gas pipelines up to 38" (965 mm) in diameter and over 0.500" (13 mm) in wall thickness. This is due in large part to having reduced the complexity of its machine control scheme.

 

Flux Cored Wires:

 

 

WHEN WELDING PIPE, CAREFULLY EVALUATE THE GAS SHIELDED FLUX CORED WIRES AVAILABLE AS THERE ARE SOME TERRIBLE FLUX CORED WIRE PRODUCTS OUT THERE.

IF YOU WANT TO SEE GOOD VERSUS MUNDANE ALL POSITION E71T-1 WIRES, COMPARE A GREAT RUNNING ESAB (ALLOY RODS) DUAL SHIELD OR KOBELCO WIRE AGAINST WHAT I BELIEVE IS A LESS THAN OPTIMUM LINCOLN, COREX OR HOBART FLUX CORED BRAND WIRES.

E-mail From John Hoffman. June 06/06:

I use all position 0.045 (1.2 mm) gas shielded flux cored wires for my pipe welds. I have been utilizing Lincoln's 71 M Outershield. I frequently get lots of porosity and worming. I would like to try something that works consistently. Ed what would you recommend?

Regards John.

Ed's answer: I have had many weld porosity and, worm track issues with all position Lincoln wires and also found that in contrast to some other wires, the Lincoln wires also offer a lower, stable wire feed range, reducing the hourly weld deposition rate potential.


IF YOU WANT OPTIMUM AND CONSISTENT WELD PERFORMANCE FROM E71T-1 FLUX CORED WIRES, CONSIDER ESAB (ALLOY RODS) OR KOBELCO WIRES. HOWEVER IF YOU WANT DEFECT FREE WELDS USE THE ADVANCED TIP TIG WELDING PROCESS.

And the best power source for gas shielded
all position E71T-1 flux cored wires is?

The lowest cost, CV MIG power source is better suited to
flux cored wires than the most costly inverters or pulsed MIG power sources.

 

 

If you want confusing European " MIG Gas Standards Data?
Visit http://www.key-to-steel.com/GuidedTour.asp


If you want European "confused" weld standards visit here.

 

To avoid weld porosity, worm tracks and hydrogen cracks.

Do not purchase flux cored wires if they are not stored in vacumm packed
sealed packages. Store flux cored wires in a warm dry location

 

E-mail 2005. Dear Ed. The weld process control data in your Management Engineers book has been great! As I read your book, it seems like you have been inside my brain. We are now breaking away from SMAW and GTAW and i will be implementing Flux Cored and MIG procedures on our pipe / pressure vessel welds. I will keep you informed and thank you for your work and process knowlege.

Matthew Panconi.
Executive Vice President.
Sylvan Piping NJ.

 

Imperial Oil Pipe Welding Research: Ed Testing MIG
and flux cored wires on Nat Gas Pipe...

IN 2003, ED MANAGED A PIPE WELD PROCESS RESEARCH PROJECT FOR IMPERIAL OIL, ALBERTA, CANADA, (THE COLD LAKE PIPE WELD PROJECT). THE PURPOSE OF THE PIPE WELDING RESEARCH, TO EVALUATE THE LINCOLN STT MODE VERSUS TRADITIONAL SHORT CIRCUIT FOR THE ROOT AND ALSO COMPARE DIFFERENT MIG, METAL CORED AND FLUX CORED WIRES FOR THE FILL PASSES.


PIPE MIG WELD WIRES: IF YOU WANT OPTIMUM, STEEL MIG WIRES FOR PIPE ROOT WELDS CHECK OUT AN ESAB OR LINCOLN L50, WIRE VERSUS THE POORER PERFORMING, COMMONLY USED E70S-X K NOVA MIG PIPE WIRES AVAILABLE FROM THYSSEN.

THE THYSSEN MIG WIRE I USED FOR THE COLD LAKE PIPE ROOT RESEARCH PRODUCED A SLUGGISH, FAST FREEZE, SHORT CIRCUIT WELD, A WELD POORLY SUITED FOR ANY PIPE APPLICATION.

DURING THE PIPE WELD AND WELD CONSUMABLES TEST, I ALSO EVALUATED A NUMBER OF METAL CORED WIRES FOR THE PIPE ROOT WELDS, AS I SUSPECTED WITH TRADITIONAL SHORT CIRCUIT TRANSFER THE METAL CORED WIRES PROVIDED NO WELD BENEFITS.

FOR THE PIPE RESEARCH PROJECT, I ALSO TRIED E80S- D2 MIG WIRES FOR THE ROOT, THESE HIGHER TENSILE MIG WIRES PRODUCED GOOD WETTING IN THE ROOT WELDS AND WITH THE LINCOLN STT PROCESS, THERE WAS NO ISSUES WITH THE E80S-D2 WIRE.

WITH SHORT CIRCUIT TRANSFER, THE ROOT WELDS WITH THE 80S-D2 WIRES PRODUCED A VERY BENEFICIAL FLAT SURFACE, ALWAYS LESS CONVEX THAN THE TRADITIONAL E70S-X MIG WIRES. KEEP IN MIND THAT THESE HIGH STRENGTH WIRES OFFER LESS DUCTILITY THAT THE E70S-X WIRE SO WHEN WELDING THE PIPE FILL PASSES, THE 80S COULD BE MORE PRONE TO HOT CRACKS IN THE SMALL ROOT WELDS. AT THE TIME OF THESE TESTS I DID NOT HAVE THE ADVANCED TIP TIG WELDING PROCESS WHICH WOULD HAVE MADE LIFE A LOT EASIER.

NOTE: IF YOU ROTATE YOUR PIPE JOINTS THE BEST PROCESS IS NOT FLUX CORED OR PULSED MIG, IT'S CONVENTIONAL SPRAY TRANSFER.

 

Set the flux cored wire weld voltage so the tip of the wire is as close as possible
to the weld (arc length) without causing weld spatter

After setting the weld wire feed rate,
fine tune the arc length with the weld voltage control.

Confused about European Pipe Specs, you should be.

A LOW COST, FAST SOLUTION TO ALL YOUR AUTOMATED AND MANUAL MIG, FLUX CORED, TIG and SAW WELDING ISSUES. Phone / E-mail. Ed has resolved over 1000 companies weld issues. Many weld issues can be resolved on the phone or by E-mail. []Are you having issues that affect your weld quality, productivity or down time? [] Are you ready to purchase weld equipment, gases or consumables and would rather not waste your money? []Do you want the best method or procedure for a specific application? Call Ed at 828 658 3574, (Eastern standard time USA). or E-mail ecraig@weldreality.com The typical phone weld resolution fee is $375paid in advance with Visa or MC. Ed is also available for short and long term contract work.

Gas Shielded Flux Cored Wires.

THE WORLD'S WORST WELD PROCESS IS SELF SHIELDING FLUX CORED WELDING. YOU MAY BE SURPRIZED TO FIND THE WELD PROBLEMS IN
THE AUTO AND CONSTRUCTION INDUSTRY

 

HOW DOES A COST COMPETITIVE GLOBAL WELDING INDUSTRY CONTROL IT'S FLUX CORED OR MIG WELDING COSTS. WHEN FEW WELD SUPERVISORS ARE AWARE OF THE WELD DEPOSITION RATE POTENTIAL OR THE WELD DEPOSITION RATES BEING ATTAINED?

• Weld deposition rates may drive weld costs, however in the global welding industry, it's rare to find a weld shop supervisor who is aware of the weld deposition rate they should be attaining for a specific flux cored or MIG application. In my unique flux cored and MIG process control program all a manager, supervisor, technician or welder has to do is provide a quick glance at any wire feed unit and they will instantly know what the welder is delivering and what the welder should be delivering.
  
  With the common USA gas shielded flux cored weld wires, be aware that for vertical up, structural / pipe / pressure vessel welds on carbon steels, you can attain a higher, stable weld deposition rate from a Kobelco / ESAB all position, gas shielded flux cored consumable than you can from a similar Lincoln - Hobart - Corex flux cored product?
  
  When evaluating the all position gas shielded flux cored wire electrodes, to attain optimum welds in any position, you must first achieve a stable, small weld droplet transfer. When evaluating all position flux cored wires;
  
  [a] Look for erratic large round weld drops that result from globular type weld transfer, this typically occurs when the weld current (wire feed rate) and voltage is typically too low. The globular weld transfer will provide excess weld spatter, cause arc and weld stability issues, cause lack of weld fusion and destroy the contact tip especially in a pipe weld over head weld position.
  
  [b] Examine how easy the flux cored weld slag can be removed from multi-pass, vee groove welds.
  
  [c] Look at the wire feed range settings and evaluate the low end capability for thin wall applications and examine the maximum weld deposition that can be attained for the common type welds attained. Ed's books and self teaching resources simplify this task and show both optimum wire feed settings and weld deposition rates.
  
  [d] Examine the optimum flux cored settings in which you can control the weld puddle especially in the overhead and vertical up weld positions.
  
  [e] Look at how much weld smoke produced at the high current settings.
  
  [f] Check how frequently you encounter commom flux cored weld defects such as worm tracks and porosity.
  
  [h] Check the quality of the wire winding on the spool and the protection from the flux cored wire package.

The purchase of the right MIG or flux cored process
control book can instantly make a welding pro.






BEST NORTH AMERICAN
GAS SHIELDED FLUX CORED WIRES.

 

For the best all position E71T-1 gas shielded flux cored wires, I recommend either the ESAB 1.2 mm dual shield wires (This is an Alloy Rod wire and Alloy Rod developed these wires). I also strongly recommend any Kobelco argon CO2 and straight CO2 wires.

While I recommend the made in Cleveland Lincoln "L50" MIG wires, I have never recommended the Lincoln gas shielded flux cored products as I found there wires have created many weld issues for me. In their optimum weld parameter range, the all position Lincoln E71T1 wires that I tested, provided erratic weld transfer which suggests a wire chemistry imbalance and also extensive worm tracks resulted. In contrast to the ESAB / Kobelco wires, the Lincoln E71T-1 gas shielded wires also provided a narrower optimum weld parameter range, with less control of low and high amp settings. For the weld shop this means that the Lincoln wire I tested, would provide less weld deposition and less weld fusion potential for vertical and horizontal welds.

 

 

Remember with flux core welding procedures, the adjustment of the arc
length is critical for vertical up weld control.

Volts too high, weld too fluid.
Volts too low, weld spatter.

 

 

WANT TO SAVE A MILLION DOLLARS ON YOUR NEXT
SMAW PIPE LINE PROJECT? CLICK ON
" ED'S REAL WORLD APPLICATIONS".

There are many engineers involved with pipe, pressure vessel fabrication and cladding that have strong negative opinions on the MIG, pulsed MIG and flux cored weld process, yet few of these engineers will have extensive MIG or flux cored weld process control expertise.

 

IF YOU TAKE THE CULTURE OUT OF THE WELD SHOP, LIFE WOULD BE BORING.

 

 

 

A comment from Mr. Bubba B. Brown Junior.
President of the BBB Oil Pipeline / Platform Inc.

" Boys, for this pipe weld project, I want you all to keep the automated and pipe weld equipment costs to a minimum. We need the ability on this project to keep the weld operation as simple as possible and although most of you are from Texas, I want the key weld decision makers in this organization to minimize the "BS" and be ready to provide me with logical justification for the purchase of any sophisticated electronic bells and whistles you feel you need to weld this pipe line.


Bubba continues. From now on I want my weld team to "ignore weld sales advice" and start make rational welding decisions for your selves. Dam it men and I use the word men loosely, we need to cut through the BS that surrounds this MIG and flux cored weld process and stop hiring wimp wristed project managers and supervisors who believe the only way to weld a pipe is the way we did it in 1960 with a Lincoln E6010 electrode.

Bubba concludes and his blood pressure is getting pretty high.You boys take note because this is the bottom line:

[] I want this organization to be known as a cost affective, dynamic company that consistently delivers optimum weld quality and delivers it's products always on schedule.

[] I want this companies weld decision makers to have the ability to differentiate between process and equipment bells and whistles and cost effective weld benefits.

[] I want this organization to ensure the weld processes utilized are made simple to operate and the equipment purchased is both logical and durable.

[] FinallyBubba finishes with, "by the way, I dont ever again want to hear, "that this is the way we have always done it".
I want each engineer and manager in this organization to go home to night, look in the mirror and repeat the following three points.

[1] I am responsible and accountable for all the weld process decisions and issues daily generated in this organization.

[2] I will do my utmost to establish and maintain Best Weld Practices for this organization and for my sub contractors.

[3] I will ensure that all weld personnel involved in this companies welded products receive the Process Control Training necessary for Process Optimization.


WE ALL KNOW THAT IN THE OIL AND GAS INDUSTRY, IT WOULD BE VERY DIFFICULT TO FIND A PRACTICAL, PIPE COMPANY PRESIDENT LIKE GOOD OLD BUBBA.

 

 

2005: The slow and often painful process evolution..

After almost four decades after the development of small diameter, gas shielded flux cored wires by Alloy Rods, we still have weld engineers and managers in the oil, power and chemical industries, who would would rather have their applications welded with stick electrodes (1.5 lbs/hr) rather than with the superior, weld quality, easier to use, more cost effective flux cored process at 8 lb/hr.

2007: ESAB has introduced a new E71T-1 (Alloy Rod) wire called theE710X. This wire works well with CO2 or argon CO2. This flux cored wire is different in that the CO2 or argon CO2 wire feed, amps and voltage relationships are almost the same. This wire therefore has an extensive, low to high optimum wire feed and amp range making it easy to use with CO2 on a very wide thickness range.

Note: Before using the ESAB wire, be aware that the moisture pick up potential with this wire may have increased influenced by the chemistry composition changes made to the ESAB wire. Before using on a large job job I recommend getting some experience with this wire and comparing it with the equiverlent Kobelco flux cored weld wire which is one of my favorite flux cored wires.



PIPE WELDS & WELD PROCESS QUALIFIED?
Today, pipe line weld decision makers have many weld process and process combination choices when welding the pipe fill and root passes.

[1]Stick root / stick fill.
[2] Stick root / flux cored fill.
[3] Stick root / pulsed MIG fill.
[4] TIG root / stick fill.
[5] TIG root / TIG fill.
[6] TIG root / pulsed MIG fill.
[7] TIG root / flux cored fill.
[8] TIG root / metal cored fill.
[9] STT root / your choice for fill.
[10] CMT or RMD root / your choice pulsed
or FCAW for fill.
[11] Globular MIG, Pulsed MIG for pipe ID and Pulsed MIG and flux cored for fill.
[12] Laser, Laser Hybrid or twin wire.

The TIP TIG process should always be given first consideration


Left photo: Ed was the project Weld Manager during construction of Africa's largest power station built in Nigeria during the 1970s. Note from Ed. One trip to Nigeria is enough for one life time.

There are always many opinions on the weld process and consumable selection for that pipe or pressure vessel application, yet I wonder how many people in the pipe industry are sufficiently "weld process qualified" to make a rational process choice for a pipe root pass when evaluating the Short Circuit, Globular, STT, CMT or RMD or the ATT weld transfer modes?

Process knowlege is just one click away. or simply call Ed in the USA at 828 658 3574.

 

 

 

IF CONFIDENT IN YOUR WELD PROCESS KNOWLEGE,
THIS WELD TEST WILL BE A BREEZE.

Weld process control is measured by weld process expertise, would you like to try this fundamental weld process control welding test?

WHEN AN INDUSTRY OR CORPORATION SUFFERS FROM WELD PROCESS APATHY OR IS SLOW TO GRASP THE WELD BENEFITS DERIVED FROM PRACTICAL WELD PROCESS OR CONSUMABLE EVOLUTION, THE WELD DECISION MAKERS WILL OFTEN IMMERSE THEIR HEADS IN THE WELD SHOP SMOKE, SHY AWAY FROM PROCESS CHANGE, NURTURE THEIR RELATIONSHIPS WITH THE LOCAL WELD SALES REP AND IMMERSE THEIR WELD SHOP IN TOO MANY WELD CONSUMABLES AND OVER PRICED USELESS BELLS AND WHISTLES.

ED TESTING MIG SHORT CIRCUIT
VERSUS STT / RMD MIG TRANSFER ON AN IMPERIAL OIL PIPE.

 

 

2009: FROM MILLER. THE MULTIPURPOSE PIPE WORXPOWER SOURCE:

 

I have to ask why would anyone waste $13.000.00 on this Miller multi-process power source, or waste $11.000on the Lincoln STT/ Power Wave to do pipe welds?. Miller believes that it's so called unique Pipe Worx has multi-process RMD - Pulsed MIG - Stick - FCAW - TIG attributes that benefit the weld shop.

The Miller RMD (Regulated Metal Deposition) process is used for the pipe root. RMD is simply an electronically modified, MIG short circuit transfer only suitable for all position pipe root welds. Miller also belives it's pulsed MIG program is ideal for all position pipe fill, however many shops who use this process will find unexpected lack of weld fusion from the pulsed welds. It's ironic that with all the bells and whistles on the Miller equipment and the too often useless wave forms on the Lincoln weld equipment, that their over priced multi-purpose weld processes will never attain the weld quality or be as simple to use as the much lower cost TIP TIG Welding process now available.

TIP TIG Welding. The world's
best manual process for pipe shop welds

 

And the best power source for all position E71T-1 wires
is the low cost traditional CV power source?

Ed's Process Control Resources.



If you want to establish Best Flux Cored Weld Practices and Weld
Process Control Training, you may want to consider.

Ed's UNIQUE BOOKS CD TRAINING RESOURCES.

 

 

 

IF YOU DON'T HAVE THE OVER PRICED LINCOLN STT OR MILLER
RMD FOR YOUR PIPE ROOT WELDS, AND YOU HAVE A REGULAR CV POWER SOURCE, CONSIDER THE FOLLOWING...

 

For internal or external "1G" horizontal rolled pipe root welds, set the a traditional low cost, ($2000) CV MIG process for "short circuit transfer" with an 0.035 (1 mm) wire with argon 20 - 25% CO2.


For the external root short circuit weld, rotate the pipe clock wise so you are welding in the vertical down weld position using the drag technique. For the root provide an 0.080 land with a 0.100 root gap. Set the short circuit wire feed rate at 250 to 300 ipm (around 11 o'clock wire feed control position). Use 16 to 18 volts. Let the contact tip stick outside the gun nozzle and hold the MIG gun at the 2 o'clock position in the center of the pipe root gap and rotate the pipe anti-clock wise. No weaves are necessary for the root pass as long as the root gap dimensions are maintained. This traditional, CV low cost MIG process is simple to operate, provides great results for this pipe root.

 

 

 

For internal 5G, position large diameter ID pipe root welds, the all position root settings can be carried out with either short circuit or the MIG globular mode, welding vertical down. For the globular mode, use an 0.035 wire, a gas mix of 25% CO2 and a wire feed rate of of 400 to 500 IPM, one to two o'clock with 20 - 24 volts.

For the external root use the short circuit mode with the parameters and edge prep dimensions mentioned for the 1G position. At the cap and overhead use an aggressive weave, while at the vert down 1 to 6 o'clock positions. For the 11 to 6 o'clock positions just use the drag technique with the wire in the center of the root gap short circuiting on the leading edge of the fast freeze weld puddle.

The pipe root pass. Using short circuit or the newer, modified short circuit requires minimal manual weld skills and typically will attain root weld speeds of approx. 15 ipm. In contrast to a SMAW or TIG root pass, the MIG process willbe done at least three to four times faster, however with the MIG processes, it's important to maintain consistent root dimensions and pipe alignment.

Thanks to the modified short circuit transfer, 11 old Jessie had no problem manual MIG welding a pipe line root pass, of course it took Ed 15 minutes to train him.

As root pass welds can be made with TIG, SMAW, pulsed MIG or modified short circuit MIG equipment, and a seperate weld process or consumable is required for the fill, perhaps its time to look at one process that is great for the root and the most effective for the fill passes. Check out the TIP TIG process at this site.

 

June 12. 2009. Welcome to the first real practical advance in manual
pipe welding technology during the last four decades." TIP TIG"

These pipe joints used to be welded with traditional TIG and the weld time was 3 hours per-joint. The welds you see in the pictures are now made with the TIP TIG process and the defect free welds took 50 minutes per-joint. In contrast to traditional manual TIG - MIG and Flux Cored, the TIP TIG process is easier to use and always produces superior weld quality. The TIP TIG process will provide Advanced TIG pipe welds at highly cost effective pulsed MIG deposition rates. Click for more TIP TIG Welding info.

An Ed excuse for a welding Joke:

 

Process expertise. See how you do with the
flux core weld quiz.

 

WELDERS WHO IN THE PAST HAVE BELIEVED THAT "SKILLS" ARE THE PRIMARY PREREQUISITE FOR ALL POSITION PIPE WELDS, NEED TO UNDERSTAND THAT WITH TODAY'S CHOICES OF TIP TIG AND MIG EQUIPMENT AND AND FLUX CORED CONSUMABLES, WELD PROCESS EXPERTISE IS FAR MORE IMPORTANT THAN WELD SKILLS.

Weld Question from UK.

Hi Ed love the site, it's a breath of fresh air. My name is Mick Brennan I work in the UK. I have been involved with the welding offshore and cross country pipelines for close on 40 years. Most of that time has been spent using Mechanized MIG Processes. Some of the processes have involved combination Internal clamping and Welding Machines. This is a fine process but it can be costly as the Pipe Ends have to be Prepped with an Internal Bevel and a Narrow Gap preparation on the outside. The money saved on less deposited metal and less welders gets eaten up with this change in Bevel Design and the costly Internal Welder. Using this equipment on shorter pipelines < 20 Miles becomes uneconomical as the pipe weld equipment is usually rented in and a mob and demob fee erodes the potential profit.

In your opinion could a Root Pass be applied to a Pipe using a Mechanized External Welding device, welding vertically down in the 5G position, 60 Degree Bevel, 1.5-2.00 mm Gap. Using a. 035 solid wire at a weld speed of 30 IPM. Wire speed 500 IPM and wire stick out of 3" with 23.5 Volts measured at the Welding Tip. In this particular area would the Pulse process be beneficial as Top and Bottom are prone to burn through and the Vertical is prone to LOP as the puddle outruns the Welding Tip?

Regards
Mick Brennan. UK.

Ed's Answer:

Mick as you know internal, pipe weld roots can be made with 0.035 MIG wires with a short circuit wire feed rate of 200 to 300 IPM with 16 to 18 volts. Also controlled globular transfer wire feed 350 to 500 ipm, 20 to 23 volts. The MIG settings you provide, WF 500 ipm - 23.5 volts are simply globular transfer.

The 3 inch wire stick out lowers the weld current and makes no sense, it does indicates a weld process out of control, and god help the gas coverage.

IN CONTRAST TO THE LONG WIRE STICKOUT USE A LOWER WIRE FEED RATE AND WELD WITH CONTROLLED WELDING CONDITIONS.

For the external root pass, with the short circuit mode welding vert down from 12 o'clock, a fixed gap of 3/32 - 1/8 is required and there is good opportunity for weld suck back and wire stick through at the root 5 - 7 o'clock positions. X Rays don't like those wire pieces sticking in the inside of the pipe. You should weave at the top and bottom of the pipe or place long tacks in the 12 and six o'clock positions to minimize the potential root weld issues.

Modified Short Circuit
versus Traditional Short Circuit.

Note: The above picture is a weld process pipe root evaluation. Ed managed this Imperial Oil, Cold Lake Canada project. The project evaluated the STT and traditional SC MIG processes and flux cored wires. The welds carried out by Imperial Oil contract welders. The STT is a low parameter PULSED MODE " that produces no spatter. STT was in the above photo used by the welder on the left. The traditional MIG short circuit transfer mode when set correctly (noted by the small amount of spatter), was used by the welder on right.

ED WELDING THE 16 inch NATURAL GAS PIPE AT 5 O'CLOCK. WITH THE PAIN IN HIS SHOULDER AND NECK HE WAS WISHING IT WAS 5 O'CLOCK.

The only problem area I had with all position, external MIG pipe root welds which were made with the traditional MIG short circuit mode and 0.035 wire, was found at the 5 - 7 o'clock root area of the pipe. At this position, during the short circuits occasionaly a piece of the weld wire would go through the root and stick inside the pipe.

The 5 - 7 pipe position would result in root welds with a slight root weld suck back and weld wire getting stuck inside the root at the over head position. The bottom line, it's difficult to control the short circuit root weld quality in the over head area. The over head root location on the pipe root pass could readily be welded during the tack operation using SMAW electrodes or the TIG process. Then while in the 5G position, the welder could use a traditional short circuit vertical down weld for the rest of the root. Both the MIG short circuit and flux cored processes can be used with argon 20-25% CO2 gas, low cost generators with CV adapters or with low cost CV MIG equipment.

MIG and Pipe Root Tacks

If on your pipe application, the required pipe root dimensions and edge preperation cannot be maintained, the root pass should be made with the SMAW or Advaced TIP TIG Welding process.

A GOOD MIG TACK PROCEDURE:With the short circuit (SC) or modified SC mode and an 0.035 (1mm) wire, place three weld tacks 50mm in length, then feather the tack start / stop edges by at least 9 mm in length. After the root pass is complete take the grinder to the length of the tacks to thin and blend the tack weld throat, (remember don't go too thin < 0.080 as the next pass may burn through. For the a MIG root pipe prep and the short circuit process, use an 0.080 land and a 3 mm root gap, the 0.080 land adds base metal to the filler which provides two weld benefits;

(1) If the root pass filler metal is stronger than the base pipe metal, the filler weld dilution with the base will lower the root weld strength and therefore provide less weld shrinkage stresses. In this situation the weld ductility will typically increase reducing the potential for hot weld cracking in the root..

(2) A slight land on the pipe bevel also adds to the process in that the weld can readily attach itself to the land and the resulting bevel fusion adds to the root depth enabling a more robust hot pass to take place As this area is the most common location for lack of weld fusion defects this is beneficial

For modified short circuit transfer, although no land on the bevel is required to make the root weld, for the reasons listed above, I would have at least a 1.6 mm land on the pipe bevel. For the root gap, I would use a 2.5 - 3mm gap and with an 0.045 (1.2mm) wire. For all MIG root welds, use back hand vertical down.

The root throat depth (approx. 0.080) of a MIG root weld supports the next hot fill pass typically made with either pulsed MIG or flux cored wire.

When the gas shielded flux cored consumables are selected for the pipe "fill" passes, pipe line welding companies should examine closely the need for costly, complex automated pipe weld units, versus a simple automated, carriage and CV generator for the gas shielded flux cored pipe fill passes.

FOR SMALL PIPE LINE PROJECTS IT PAYS TO KEEP IT SIMPLE AND COST EFFECTIVE:

Take a look at your process and equipment choices. Consider a $130,000,00 complex, automated, computerized, pulsed MIG pipe line weld package or a simple to operate mechanized, carriage / track with a CC- CV generator and all position gas shielded flux cored wires for approx. $30,000. The flux cored wires, two procedures and the generator with the low cost mechanized unit package could provide the following benefits;


[a] When manual or automated welding on pipe lines using flux cored wires, one volt / wire feed amp weld setting is all that will be required for the pipe fill, flux cored passes. The weld speed and weld weave width will of course change.

When pipe weld operators use many flux cored or MIG "weld parameter combinations" for multi-pass, pipe fill welds, it's an indication the people who set the equipment are typically not in control of the welding process.

[b] The simplicity of the two weld controls used with the flux cored process, allows the manual or automated pipe weld operator "easy control and weld adjustment of the weld process" To optimize this pipe welding process I recommend my MIG and flux cored weld process control books and CD resources ) that explains why on this operation two weld procedures are all you need.

[c] The flux cored process provides greater weld fusion than any pulsed MIG mode, it will also provide less porosity potential and require less welding skills.

[d] For pipe fill passes only. A simple low cost mechanized carriage attached to the track that straddles the pipe would sell for $10,000.00 to $15,000.00. The weld carriage should have the weld controls necessary for weld speed and weld weave controls. The weld gun would be hooked up to a traditional, field wire feeder that would be attached to a CC / CV generator. For this weld, there is no need for a complex, pulsed MIG electronic weld power source that offers 100 weld schedules and a dozen different ways to weld steels, stainless or aluminum.

FOR ALMOST 40 YEARS FLUX CORED HAS BEEN A WINNER, IT'S JUST THAT MANY IN THE WELDING INDUSTRY FAILED AND STILL FAIL TODAY TO RECOGONZE THE FCAW PROCESS POTENTIAL...


The use of gas flux cored wires for all position pipe fill passes, will in contrast to any MIG weld transfer mode, be simpler to use, easier to operate and produce higher weld deposition rates (lower weld costs) with superior side wall fusion.

Note: If optimum flux cored consumables are selected and the flux cored weld data is correctly applied, as the following photo indicates, all the welds will be made with one set of weld parameters with changes only for the weave data. If the weld data is correct the pipe weld slag should fall off almost without assistance.

E71T-1 FLUX CORED WIRE. EASY SLAG REMOVAL IFYOU USE
THE RIGHT WELD WIRE AND OPTIMUM PARAMETERS:

If welding the pipe line root weld on the "inside" of the pipe, the traditional low cost, CV, MIG equipment or a CV adapter on a CC generator may be used with a MIG wire using;

[1] a high short circuit setting,
[2] a controlled low globular setting,
[3] a low spray transfer setting with less than normal spray transfer weld volts.

Note: For 1 to 3, the 0.035 (1 mm) E70S-3 wire with argon 15 to 25% CO2, will provide the greatest
control in open root pass welds.

Ed's "Clock Method" simplifies MIG
and Flux Cored process control training.

 

The following statement is one many highly skilled SMAW pipe line welders will not want to hear, however like it or not, it's weld reality.Using the modified short circuit mode or traditional short circuit process for the root, a none-welding individual who is drug free, has good vision, good dexterity and the right attitude can be trained in less than 2 days to weld an all position pipe root that will meet any pipe code weld requirement.

A good welder is more than the sum of his skills, a good welder combines skills
with weld process, technnique and consumable knowlege..

 

Lincoln Invertec STT II

Featuring the Surface Tension Transfer (STT) Process
List Price: $7706.00

This over priced STT II power source, combines high frequency inverter technology with Waveform Control Technology™ to provide a better welding solution than traditional short arc MIG on pipe root welds. This process provides no real world weld benefits to most other common steel applications making this power source a costly, piece of equipment to have sitting on the floor of a weld shop.

2006: Note: Once competitive MIG power source manufactures wake up, they will develop similar pulsed arc characteristics / parameters to STT from the available pulsed weld technology and create a pulsed program suited to pipe root welds. The reality will then be that the Lincoln STT power source will cease to exist..


The STT MIG root will require a root gap of 1/16 to 3/16 (3/32 to 1/8 is optimum). Provide a land of 1/16. The land is not necessary however it adds metal to the root increasing the root weld depth. With this land, a root weld throat of of 0.125 to 0.175 will result. The next weld can be made with the 0.045 flux cored wire.

STT PIPE ROOT. PULSED PARAMETERS:
With that 0.045 (1.2 mm), E70S-6 wire and argon 10 to 25% CO2 set the parameters in the following approx. range.

Peak 320 - 360 amps, Back Ground40 - 60 amps, Wire Feed110 - 160 ipm.

Start out with Peak 325 amps. Back Ground 45 amps.
0.045 Wire Feed set 120 - 140 ipm.

Note: The optimum average modified STT current for the pipe root is also the same as the optimum short circuit current for the same application. To anyone who understands the relationship between weld current and wire feed rates, no surprise there.

2004:SMAW pipe welders, rather than resist the inevitable cost effective process changes for pipe line welds, I would recommend you reach out and embrace the manual / automated modified pulsed / short circuit transfer modes along with the flux cored process and strive to become expert "manual or automated pipe line weld technicians".


E-Mail. Feb 2004. Mr. Ed Craig:

I have been welding for ten years but have never, like you say,really known the proper weld parameter settings. What would be the optimum manual flux cored weld parameter settings using .035 wire welding 6" schedule 180 pipe in the 6G position on carbon steel? I have never welded with FCAW to make a root weld in a pipe. I need to take a test on Monday and sure could use this information. I think your book " Gas Metal Arc and Flux Cored Welding Parameters " is the book I need to have and do plan to buy it. Thanks for your help and your website.

Sincerely,
Larry Fritsche


Ed's reply. I must get two letters like this every week. Two days before the welder takes a test he suddenly realizes he will not know where to set the optimum MIG or flux cored weld parameters for his critical pipe test and god help him if he uses the flux core wire on the root. I provided this data to Larry.

I WOULD ENCOURAGE ANYONE WHO MAKES A LIVING OUT OF MIG OR FLUX CORED WELDING TO INVEST IN A PROCESS CONTROL CDs and BOOKS SO THEY CAN INVEST IN THEMSELVES.

 

Fronius Twin Wire Pipe Welding
with 4 Heads 8 Weld Wires

For those of you that feel you have mastered the single wire MIG process, or the higher deposition rate flux cored process that offers 8 to 12 lb/hr on pipe fill pass welds, perhaps are you have the process knowledge ready to set the 8 wires running on these four twin units that provide an average weld deposition rate of 60 lbs/hr. Before you step up to this level, I would recommend you grasp the requirements of single MIG wire welding using my self teaching MIG process control resources .

 

 

 

 

HOW LONG SHOULD IT TAKE FOR AN INDUSTRY TO
DEVELOP BEST WELD PRACTICES?

 

IT WAS DURING 1950. THE LOCATION 30 MILES NORTH OF HOUSTON TEXAS. WHILE PIPE WELDING WITH A E6010 ELECTRODE, RIP VAN SMITH, A 40 YEAR OLD, EXPERIENCED PIPE WELDER FELL ASLEEP IN A 48 INCH PIPE. WHILE RIP SLEPT THE PIPE WAS SEALED.


Being a Texan RIP had amazing powers and fifty years later RIP woke up from his oil immersed deep sleep. The unique chemicals inside the pipe had not allowed RIP to age. After crawling along the pipe for a 100 miles, RIP found a maintenance access hole. RIP crawled out of the pipe and his first stop was BeBees Barbecue Bar where he purchased a Barbecue triple Burger and washed it down two cases of Bud.

After a short nap and a long bath RIP decided to apply for a pipe line welder position on a new, natural gas pipeline that was running straight through the center of down town Houston. Wearing a new Harley tee shirt, recently stained with Bud beer mixed with a BeBees famous Brown sauce RIP took a bus out to the pipe site office.

The pipe site weld supervisor was impressed with RIP as he pulled out his brand new leather gloves and shield. With the aid of his new 10 inch bowie knife, RIP with a single strikepierced opened the metal lid of the E6010 electrodes.

RIP smiled as he held the electrode under his nose and sniffed the sweet smell of his next pay check. With a flick of his wrist he inserted the electrode into the holder and his heart never missed a beat as he commenced to produce a great vertical down welds on the 24 inch pipe.

RIP quickly completed the pipe test and the pleased supervisor hired him on the spot. That night in celebration, RIP made mad passionate love to Mary Lou Ellen, a waitress he met at BeBees. Being a Texan RIP made love for eight hours, as Mary Lou lay in a state of exhaustion, RIP leaned back on the pillow, lit a long Cuban cigar and said out loud "life don't get better than this"

There are few industries that today complete it's fundamental manufacturing tasks the same way they did 50 years ago?

I hope the present day managers, welders, technicians and engineers in the pipe and pressure vessel industry will be more open minded to the practical, cost effective weld process changes that can improve both their weld quality and productivity.

 

"WELD CODES"

Weld decision makers often look to weld codes to provide practical, pipe welding advice and recommendations. The weld reality is the weld sections of many weld codes have been written by weld code committee individuals who's strength may not be in the weld processes under discussion.


Some of the major weld code committees in North America are likely to have individuals that are more interested in marketing their companies weld products than they are in writing meaningful, logical weld spec data. Other committee members would benefit if they spent a little more time behind a welding shield before they make their flux cored or MIG weld comments.

50 YEARS AFTER THE INTRODUCTION OF THE "MIG PROCESS", AND 30 YEARS AFTER THE INTRODUCTION OF FLUX CORED ELECTRODES, THE NEWLY REVISED 03/2001 "AP1 CODE 582" STATES THE FOLLOWING ABOUT MIG AND FCAW PIPE WELDING.

API. 5.2.3 Pulsed Gas Metal Arc Welding (GMAW-P. The pulsed process may be used for any material thickness. Commentary: Whenever the welding system is changed or the settings on existing equipment are "significantly altered", the fabricator should verify weld properties. The extent of verification or testing should be as agreed between the purchaser and fabricator.

PULSED MIG AND WELD PARAMETER REALITY.

In contrast to the traditional, simple, two weld parameter MIG or flux cored weld processes, there are many weld parameter essential variables that can be readily changed with the pulsed mode. The API code warns against a "significant change" in a pulsed weld settings. What is "significant" weld parameter change?

Keep in mind that at best the pulsed process will only provide marginal weld fusion on vertical up welds on part thickness >6 mm. From my weld process perspective, "a minor pulsed parameter change" can have a significant impact on side wall weld fusion. It's an ironic fact that few weld decision makers or welders understand the influence of the pulsed variables, wall thickness and weld fusion potential.

In that MIG and flux cored weld shop or out on that pipe line, you will find the majority of weld personnel do not fully understand the influence or the relationship of the pulsed MIG wire feed rate, the weld speed, voltage, the pulsed frequency, the peak and back ground current on the MIG arc plasma and resulting weld fusion potential. With all these pulsed variables in a pipe shop who in the shop is going to determine what a significant weld parameter change is?

While on the subject of pulsed, most codes do not address "mechanized versus manual" pulsed and traditional MIG weld inconsistencies".

When a code stipulates that a fusion sensitive weld process like pulsed MIG is OK for any pipe thickness, the code is sending the message that this process is recommended for both "manual and mechanized" welds.

Controlled weld speeds, fixed arc length and a controlled mechanized weld weave have a lot to do with the success of MIG weld using any mode of weld transfer. However you can be sure the traditional "manual weld weave inconsistency" would make the pulsed process a poor choice for pipe fill welds in contrast to the superior weld fusion, gas shielded all position flux cored electrodes.

ANOTHER SECTION OF THE CODE.

API. 5.2.2 Short Circuiting Gas Metal Arc Welding (GMAW-S).

The use of GMAW-S shall be limited to the following conditions:

a]. The short circuit process shall not be used for branch connections or socket welds.

(What if there is a good size root to fill in?)

b]. For vertical welding, the root pass and second pass progression for a material of any thickness may be either uphill or "downhill".

(Have you tried uphill with short circuit?, if so you would not recommend it.)

c]. The fill and cap pass for butt or fillet welds may be welded With this process provided the thickness of any member does not exceed 3/8 in. (9.5 mm) and vertical welding is performed with uphill progression.

(Any short circuit welds made uphill on parts over 3/16 >5 mm are sure to end up with inconsistent weld fusion)

d]. What about the weld gas? The API code does not spell out the MIG gas mix that must be used with the short circuit process or pulsed on pipe welds. Use short circuit with argon <10% CO2 and you can weld in any position and almost guarantee lack of fusion on any parts > 1/8 (>3 mm), (none gap welds).

e]. Why is it that the API code will stipulate where a process can be used but will not stipulate a simple thing like weld parameter limitations for that consumable or process?

(Is it possible the code committee are not aware of this data)?

Finally the API code makes no mention of the higher energy MIG globular or spray transfer modes, does that mean they can or cannot be used. Spray transfer can be an excellent method for a rotated hot fill pipe pass and globular is great for ID roots or hot pass welds.

To repeat an important point .


IF A CODE DOES NOT OR CANNOT PROVIDE THE COMPLETE, FUNDAMENTAL REQUIREMENTS OF A WELD PROCESS RECOMMENDATION, THE WELD REALITY IS THAT CODE SHOULD PROVIDE NO WELD RECOMMENDATIONS OR WELD RESTRICTIONS.

WELD CODES SHOULD PRIMARILY BE CONCERNED THAT WELDS ARE CORRECTLY PRE-QUALIFIED AND CONCERNED WITH THE "CONDITION OF THE FINISHED WELD PRODUCT".

2007: I REALIZE THE IMPORTANCE OF THE PIPE AND PRESSURE VESSEL WELD CODES AND THEIR CONTRIBUTIONS. MY POINT IS HOPEFULLY THAT THE NEXT GENERATION OF WELD CODE / SPEC REVISIONISTS WILL SEE THAT THEIR MIG AND FLUX CORED WELD DATA RECOMMENDATIONS DOES NOT GENERATE THE PROCESS CONFUSION THAT THEIR PREDECESSORS HAVE GENERATED.

 

LIKE SOME INFO ON HOW TO PREVENT ARC BLOW?

 

Question:

Flux Cored Pipe Weld.

Ed here in Canada we are welding a 4 in. A335-P22 pipe to A234-WP22 pipe. We are using a E-91T1-B2 0.045 in. dia. Gas-shielded, flux-cored wire with a 75 Ar - 25 CO2 gas mix. We preheat the pipes to 400° F and do not exceed 550° F for the inter-pass weld temperature. The flux-cored weld current range is from 150 - 225 A. Voltage ranges from 24-29. The supervisor says all his welders have experienced massive worm tracks in the center of the weld bead usually on the cap pass. Yet it doesn't happen on every weld. I told the supervisor to reduce the weld voltage and this seemed to fix the problems. Could you explain why?

Ed's Answer:The worm tracks which are accumulated porosity, typically appear in an irregular line on the weld surface. The tracks result from moisture in the electrode wire flux. This is a common problem especially with flux-cored electrodes purchased at bargain prices from wire manufacturers that simply don't give a dam.

However even with quality flux cored consumables the moisture can get into the wire flux due to inadequate weld wire storage or from no protection for the wire when it's out in the shop.Take note of the flux-cored wire manufacturers storage and baking recommendations.

The reason you see the common worm track weld problem in the pipe weld cap pass, is that this weld pass is typically the one with the least weld depth and therefore, has the fastest weld freeze, providing the opportunity for trapping porosity.

Using a slightly longer wire stick out will preheat the weld wire and this sometimes helps. I suggest you use the highest possible weld current, slow down weld travel rate, and increase the weld depth. Turning down the voltage, which is reducing weld energy, is not likely to help unless you end up with a more convex weld — a weld with increased weld depth.

 

 

IF YOU ARE LOOKING FOR RESOURCES THAT WILL ALLOW YOU TO INSTANTLY SET THE WIRE FEED AND VOLTAGE CONTROLS FOR ANY GAS SHIELDED FLUX CORED WELD CLICK HERE.

Question:

FLUX CORE WIRE SIZES:

Ed we will be welding various diameter stainless / steel pipes in all weld positions, some welders like 1/16 and other welders like 0.052, apart from welder preference is there a logical approach to the selection of an optimum wire diameter.

Ed's Answer. Current compatibility with the part thickness and the weld deposition rate attained is what drives the selection of the correct size weld consumable. For pipes with a wall thickness < 1/2, without question the 0.045 1.2 mm gas shielded, all position flux cored wire welding in the 140 to 220 amp range 24 - 26 volts provides welders with the greatest control of the weld puddle particularly in the overhead position. For pipes with wall thickness > 1/2 and diameter consider the 0.052 but keep in mind the 0.045 is always easier to use.

Question:

FLUX CORED DRIVE ROLL GROOVES:

Ed I believe you need different guide rolls for different MIG wire and flux cored types, what's recommended?
JH. Manchester UK

 

 

 

Ed's Answer:

[] For solid hard MIG wires use a vee groove built for the wire OD.

[] For flux core wires use a vee groove with at least on roll providing a knurled surface to improve the grip. Watch you do not apply too much drive roll pressure to these wires.

[] For aluminum MIG wires a U groove with smooth surface again don use excess drive roll pressure. With aluminum ensure minimum gaps between the inlet, drive rolls and outlet guides to avoid buckling. If using a regular MIG gun use a hard plastic liner and a maximum gun length of 10 feet.

Question.

FLUX CORED TECHNIQUE:

Ed, when welding fillet welds with the E70T-1 gas shielded wires > 1/16 (>1.6MM) do we push or pull the gun?


Ed's Answer. If using the <1/16 (<1.6 mm) wires and welding fillet welds you can push or pull, however I would use back hand for all fillet welds with all flux cored weld wire sizes.

 

 

THE SELECTION OF FLUX CORED WIRE TYPE:

In many weld shops the first choice FCAW consumable is the "all position E71T-1 wire. This is not the best choice if many of your welds on steels > 7 mm are made in the flat and horizontal weld positions. In contrast the 1/16, E70T-1 basic slag wires, provide a more stable higher weld parameter range, a superior weld surface, have more deoxidizers, have a thicker, slower freeze weld slag that typically results in superior weld surface, rather than the irregular pock marked weld surface from the E71T-1 wires. The E71 wires are ideally suited to vertical / horizontal welds, and that's the place to use them.

Note: Unlike MIG wires which have subtle differences in arc characteristics and weld pool dynamics, you will find a tremendous weld performance difference with flux cored products from the different flux cored wire manufacturers.

Note: For those of you who are using metal cored wires on your steel applications, please note they offer no real world weld benefits for the applications in your shop.

LARGE FLUX CORED WELDS AND WELD CRACKS

Ed my company welds with 3/32, E70T-1 gas shielded flux cored wires. The manual welds are single pass fillet welds from 3/8 to one inch. The welds are made on parts in which many welds are concentrated in a small area. The welds are made in positioners and made in the flat weld positions. The typical flux cored weld parameters are 400 to 500 amps and 30 to 32 volts. The carbon steel parts we weld vary from 6 to 50 mm and are used in heavy duty construction equipment. The parts are subject to excessive variables loads. In the past month we have had extensive field weld cracks. The cracks are typically in the weld's heat affected zones. Is this low hydrogen cracking?

Hydrogen may have an influence however the weld procedures used are likely the real root cause. With many weld shops managers there is a common point of view that when it comes to welds "bigger is better"

Large, > 5/16 "single pass" fillet welds require "slow manual weld speeds" of 4 to 8 ipm is typical and 3/32 wires will use weld current up to 500 amps with 30 volts. These parameters can result in abnormal weld heat build up in theparts welded. The high weld heat can be further influenced by possible lack of interpass temperature controls. Excess weld heat can cause excess grain elongation in the parts heat affected zones and welds, weakening the load bearing ability of the steel.

 

HOW MUCH WELD HEAT IS ENOUGH?
(joules = volts x amps x 60 divide by weld travel speed)

Compare the weld joules heat input generated by the flux cored wires and controlled MIG and flux cored welds.

Typical MIG and flux cored welds should be made with a weld joules input of approx. 20.000 to 40.000 joules per inch.

When single weld passes larger than 5/16 are made with large consumables requiring high weld current, the resulting weld joules per-inch can be in the 100.000 to 200.000 range. When more than 60.000 joules per inch are attained in a weld, apart from a potential reduction in the steels mechanical properties, the wire chemistry and weld mechanical properties can also be negatively influenced by excess weld heat which can result in vaporization / reduction of critical weld alloys.

FOR MOST MIG AND FLUX CORED APPLICATIONS.
IT'S LOGICAL LIMIT THE SIZE OF THE SINGLE PASS MIG
AND FLUX FILLET WELD TO 5/16.

Use logical size weld consumables that enable lower weld current with good weld deposition rates . Most important is remember weld speed are limited by the the size of the fillet welds, this is key in dramatically reducing weld heat input.

For flat and horizontal fillet welds on steels with mill scale, the world's most effective flux cored weld consumable size is the 1/16 - 1.6 mm, type E70T-1. With this wire and a single pass limit of 5/16 , the weld operator would weld with approx. 320 to 380 amps, (average 14 lb/hr) x 28 volts x 60 at an average weld speed of around 12 ipm resulting in approx. 50.000 joules per inch. For those concerned with weld production, remember the smaller weld wires and welds enable greater weld control and approx. two hundred percent faster weld speeds than that attained with the 3/32 wires. Also smaller weld sizes and multi-pass welds offer the unique benefits of weld temper beads. Typically the multipass welds when made in weld heat controlled conditions will provide a stress relieve and beneficial grain refinement.

LOGICAL INTERPASS TEMPERATURE WELD CONTROLS?

On any steel structure subject to excess weld heat a little welding common sense goes a long way. Interpass temp controls are necessary to control the weld heat build up in both the welds and parts. I would recommend for the low carbon steels that require multi-weld passes a max. interpass temperature of 350 to 400F. The weld temperature should be taken within one inch from the weld edge.

WELD BENEFITS FROM 1/6 (1.6mm) FCAW WIRES:

In contrast to the 3/32 wires:

[A] The 1/16 flux cored wire enables both the push (forehand) and back hand techniques allowing for superior weld control. In contrast the 3/32 wire allows only the back hand technique which is required to stop the fluid weld puddle passing the weld wire.

[B] The 1/16 wire can provide high deposition welds with the benefit of lower weld current, something that benefits both the welders and parts.

[C] The 1/16 wire provides superior control of the weld puddle which is especially important to 5/16 "horizontal" fillet welds.

[D] The 1/16 wire provides flexibility for the variable steel thickness sizes > 6 mm found throughout the plant.

[E] The 1/16 wire reduces weld smoke, weld undercut and weld spatter potential.

 

See the incredible accident with the world's
largest welded machine in part 2 of this section.

Visit most global ship yards and you will see that the most common MIG power source is an Inverter, yet these over priced power sources are the worst possible MIG weld equipment choices for welding flux cored welds on any type of sea going naval vessels. The reasons are in Ed's flux cored welding training resources.

 

All position Structural Plate
and Pipe Welding Data.

 

See how you do with the
E71T-1 flux cored weld test.




Use Ed's MIG and flux cored process control to optimize your
MIG and flux cored PQR and weld procedures.

Don't forget to visit the first real practical advance in manual
pipe welding technology during the last four decades.
TIP TIG Welding"