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

MIG Welding Thin Gage Metals.

This actually happened because the US plant that made the bombs did not
know the difference between short circuit welding and spray transfer welding .

HAVE YOU SEEN TIP TIG? THIS PROCESS PROVIDES LESS WELD HEAT AND BETTER
WELD QUALITY THAN TIG AND PROVIDES THOSE WELDS AT MIG WIRE FEED RATES.




Click on the Evolution of TIG icon if you want a TIP TIG brochure.




Short circuit welding or pulsed MIG Welds on
CARBON STEELS AND STAINLESS STEELS.

2006: As the pulsed MIG process evolved over two slow painful development decades, the utilization of short circuit decreased for gauge applications, however in contrast to pulsed, the short circuit welding process offers many unique superior weld attributes for thin gauge applications.

Note: This site has been a weld blog long before the word blog was discovered. This site cuts out the salesmanship from an industry that depends on sales advice. This site brings you my weld process expertise gained over almost 50 years. This site brings the opinions of others in the weld industry that also strive to see that industry gain the respect it deserves.




During short circuit welding transfer, unlike the open arc pulsed, globular and spray transfer modes, the unique short circuit arc spends a good portion of it's time in the arc off condition. When the electrode positive short circuit weld wire makes contact with the negative grounded part it's in the arc c off condition. This condition is controlled by the power source slope. At the short circuit the resistance to the current is lowered, the weld voltage drops and the current rises to the slope limit. The short circuit current rise is sufficient to melt the wire tip and form an arc which results in the formation of a fluid droplet that quickly develops on the MIG wire tip. As the wire feed is constant, the weld droplet is drawn by capillary action to the surface of the weld. The weld droplet is detached and the wire is driven to the weld to repeat the arc off, arc on cycle which typically occurs 60 to 120 times per-second

Note: With argon gas mixes, the argon mix gas plasma partially covers the fluid droplet. In contrast with straight CO2, the CO2 plasma would be at the bottom of the weld droplet, supporting and disturbing the drop till it gets larger and transfers in an erratic manner. One hundred percent CO2 = excess spatter and erratic globular transfer.


A UNIQUE ATTRIBUTE OF SHORT CIRCUIT TRANSFER WELDING: The short circuit mode is the only weld metal transfer in which the arc goes on - off. The "arc on - off" this attribute is a logical weld benefit on thin gauge, or applications which require a gap be bridged.

If welding stainless and steel thin gauge applications short circuit is an excellent weld transfer mode, however stainless produces more sluggish welds than carbon steel welds. The sluggish welds welds are noted on stainless parts > 0.080.

On robot stainless gauge applications > 0.070, low spray parameters and an 0.035 wire can be used. Pulsed MIG is applicable when manual welding > 16 gauge stainless parts.


Note for those of you that have not visited the TIP TIG section of this site you may not be aware of a process that delivers the highest ppossible stainless or alloy weld quality,

A Short Circuit and Pulsed Transfer Weld Consideration. Short circuit welding transfer available from a low cost, constant voltage, (CV) traditional MIG power source with an 0.035 (1mm) wire, is ideally suited for all manual steel applications 20 to 12 gauge. Weld Fact: A benefit of the pulsed mode for many thin gauge applications is a lower cost, easier to feed, 0.045 (1.2 mm) carbon steel or stainless wire may be used instead of the 0.035 (1 mm) wire.

Designers and manufacturing engineers often suffer from a lack of MIG weld process knowledge and that can lead to dramatic weld cost consequences.

When welding thin, carbon steel or stainless robot welded parts < 2mm you may find;

[a] unacceptable part part tolerances,
[b] poor part fixtures,
[c] inappropriate weld joint designs,
[d] poor consumable size selection,
[e] poor weld parameters and technique selection.

Of course items A to E will have weld issues and cost ramifications from weld burn through, distortion, weld rejects and extensive or rework. To add to the thin gauge weld issues, it's a sad fact that the majority many automotive and truck manufacturing plants that use MIG welding robots, lack the engineering ability to select the correct size MIG wire or weld transfer mode for the application.

ED'S MANUAL AND ROBOT WELD PROCESS CONTROL RESOURCES.

ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES. A FEW OF HIS PROJECTS,
FORD F 150 FRAME - VOLVO CAB - CORVETTE FRAME- HARLEY FRAME - NEW BEETLE SEATS
AND THE ROBOT WELDS ON THE WORLD'S LARGEST CATERPILLAR TRUCK.

My unique manual and robot MIG Process Control Training Programs

CARBON STEEL GAUGE APPLICATIONS:
GUAGE THICKNESS, IDEAL WELD TRANSFER MODE,
IDEAL MIG WIRES SIZES AND WELDING GAS SELECTION.

STEEL GUAGE CHART, WIRE SIZE & WELDING GAS MIXTURE

E-mail. Weld Question, 06 /20/03

Hi Ed, I would like to know what the critical factors are that determine fusion to the base metal. I wonder if short circuit transfer simply won't put heat into the base metal fast enough to achieve fusion on anything greater than gauge thickness. Right now I have a single phase, Miller 185 power source. We weld steel and silicon bronze base metal for architectural work, balconies, railings, etc. Typically we are joining 1/2 to 3/4 inch square to 1/2 x 1 to 1/2 x 2 with single and double bevel prep. I find I must run in globular mode with the 0.035 wire we use. I don't think the Miller 185 will get me into spray transfer and am trying to decide if a machine in the 250 amp class is the solution. We are currently stuck with single phase power . What is your take on all this?

Regards, Erik Lander.

Ed's reply. Erik, with manual short circuit transfer, depending on the steel application you should be concerned about fillet weld fusion on components over 0.100 and consider pulsed, controlled globular or spray for these applications.

Using argon 10 to 20% CO2, an 0.035 (1 mm) steel wire will require >200 amps to attain optimum spray transfer, that's why the CV. "250 amp" power source is a popular equipment choice. You can get a lower spray transition current if you use argon oxygen oxy mix (try 5% oxy ). With argon oxy mixes you will get into spray around 180 amps, however, note this gas mix is not suited for short circuit transfer. If you really want to get into spray with argon CO2 mixes on your power source, you would have to use an 0.030 (0.8mm) MIG wire. Expect wire feed issues with this small wire.

A logical solution with your power source when welding carbon steel welds, give considerations to an 0.035, E71T-1, gas shielded flux cored wire with argon - 20 % CO2. With these consumables and your small power source you could weld any metal thickness in any position. Good luck Ed.

ROBOT MIG AND MANUAL MIG DATA DIFFER:

MIG welding data recommendations can change dramatically when changing from manual to automated welds. In contrast to manual welding, when welding thin gauge applications with robots, the welds typically can be made with "higher weld travel speeds" which allows higher weld current settings or different weld transfer modes.

Pulsed spray transfer " allows manual / robot welds to be made on carbon steel or alloy steels in the thickness range of 0.045 (1.2 mm) to any thickness.

Robot welds using 0.035 (1mm) wire with regular "spray transfer" set at low welding spray parameters can be used on parts as thin as >0.070, >1.8mm. No weld gaps and short weld lengths preferred.

Globular Benefit: For welding those exhaust components or Harley bike frames with "weld gaps" in which it's difficult for weld spatter to attach, an alternative weld transfer mode is "globular transfer". For globular transfer use 0.035 wire typically set at 400 to 600 ipm with a weld voltage range of 20 to 24 volts. This mode provides low to medium weld energy at higher weld deposition than short circuit.

I BELIEVE THERE ARE THREE BOOKS EVERY MIG WELDING DECISION WILL BENEFIT FROM.

[1] MY MIG AND ROBOT WELD PROCESS CONTROL BOOK.

[2] MY MANAGEMENT AND ENGINEERS GUIDE TO MIG.

[3] MY MANUAL MIG & FLUX CORED BOOK.

Note: These books and my MIG training video and unique process control CD's are found in the training resources section of this site (click here).

My process control training resources, simplify the selection of optimum MIG wire feed and volt settings for all common electrode diameters used on manual and robot applications. The process control welding CD's will provide your robot personnel and welders with the ability to instantly set the optimum MIG weld transfer modes and weld parameters for any steel application.

Two important steps for effective weld process controls.

[1] Avoid weld sales advice.

[2] Take a logical process approach in selecting the optimum MIG wire diameter for your applications.

If we have traditional CV MIG equipment, the 0.035 or 0.040 (1 - 1.1mm) MIG wire diameters provide a short circuit weld current range that is best suited for the common thin gauge, steel and stainless applications. We should avoid using smaller MIG wires as they are not necessary and they can create wire feed issues. If you purchased a pulsed power source, a prime benefit will be that it it allows the use of the lower cost 0.045 wires for thin gauge applications.

2000: As many auto / truck managers believe when it comes to welding "bigger is better" you will find one common major weld issues found in global auto / truck plants during the last two decades. That issue is the use of MIG wires which are "too large" (0.052 - 0.062) and also use the use of self shielded flux cored wires, electrodes that should never be part of a weld in which engineers have control. To attain optimum weld transfer from large diameter MIG wires requires high weld current and typically the current required will not be compatible with the thin gauge size welded. My process control training programs teach these requirements, all we need is managers who understand the importance of this topic and will implement this type of training for their employees.

THE WORLD'S WORST WELD WIRES AND A PROCESS CHOICE
FOR MANY IN THE AUTO / TRUCK INDUSTRY

SELF SHIELDED FLUX CORED WIRES AND WELD PROCESS
IGNORANCE CAUSES MILLIONS IN UNNECESSARY WELD COSTS:

2006: WHEN I SEE SELF SHIELDED FLUX CORED WIRES USED IN ROBOT CELLS, I KNOW THE PLANT SUFFERS FROM LACK OF WELD MANAGEMENT AND PROCESS IGNORANCE.

AT THIS TIME BOTH CHRYSLER AND GM MANAGEMENT ARE REQUESTING USE OF THESE WELD WIRES FOR THEIR GALVANEALED PARTS WHICH IS IRONIC AS THESE WIRES OFFER NO BENEFITS FOR GALVANEALED. THANKS TO THE WELD ISSUES THE USELESS SELF SHIELDED WIRES GENERATE, THESE WELD CONSUMABLES HAVE COST AND WILL COST CORPORATIONS MILLIONS OF DOLLARS ANNUALLY IN LOSS OF ROBOT / MANUAL WELD PRODUCTIVITY, REJECTS, WELD CLEANING, FUME ISSUES AND WELD REWORK.

MANY PLANTS USE 0.045 (1.2mm) MIG WIRES AND THE CV SHORT CIRCUIT MODE TO ROBOT WELD PARTS LESS THAN 0.080. THESE WIRES ARE THE FREQUENT CAUSE OF WELD BURN THROUGH ISSUES.

MANY PLANTS, ESPECIALLY AUTO / TRUCK FRAME PLANTS WILL ROBOT WELD PARTS
1 TO `4 mm AND USE AN 0.052 (1.4 mm) WIRE, YET THE SPRAY CURRENT WITH THESE WIRES IS BETTER SUITED TO WELDING PARTS > 5 mm


AT THE INFAMOUS "QUALITY IS JOB 1" FORD FRAME PLANT IN DETROIT, MIG WELDING THE TRUCK FRAMES WAS MORE OF A COMEDY SKIT THAN THE ENGINEERED APPLICATION OF A WELD PROCESS. THE FORD PLANT AND ITS ENGINEERS AND MANAGERS SIMPLY HAD NO UNDERSTAING OF THE REQUIREMENTS OF ROBOT WELD PROCESS CONTROLS AND THE PLANT CONSTANTLY USED UNDERTRAINED EMPLOYEES AND OVERSIZED MIG WIRES ON IT'S ROBOT MIG WELDING TRUCK FRAME LINES.

HOW YOU IMPLIMENT "QUALITY IS JOB 1". AT THE FORD PLANT YOU WOULD FIND AN EMPLOYEE AT THE END OF THE ROBOT LINE. HIS JOB WAS TO USE A CHEAP SWEEPING BRUSH, DIP IT IN BUCKET CONTAINING YELLOW PAINT AND TRY TO MARK THE NUMEROUS BAD WELDS ON THE FRAMES AS THEY PASSED AT THE RATE OF ONE A MINUTE. THIS PLANT AND OTHER FORD FACILITIES HAS FOR DECADES HAD THE PROUD ENGINEERING ACHIEVEMENT OF NEVER PRODUCING A ROBOT WELDED FRAME, WITHOUT EXTENSIVE WELD REWORK.


OVERSIZE MIG WIRES WILL NOT ALLOW THE USE OF SPRAY TRANSFER WHICH DID NOT MATTER FOR MANY COMPANIES THAT DID NOT KNOW WHAT SPRAY TRANSFER WAS. OFTEN THE OVERSIZED WELD WIRES END UP BEING USED IN THE GLOBULAR TRANSFER MODE. GLOBULAR TRANSFER WAS VERY COMMON AT FORD, GM, DANA, TOWER AND CHRYSLER PLANTS. THE GLOBULAR WELDS WILL LACK WELD FUSION, CAUSE EXCESS SPATTER AND CAUSE CONTACT TIP ISSUES RESULTING IN EXCESS ROBOT DOWN TIME.

Weld Fact: Welding carbon steels or stainless steels with an 0.035 or 0.045 (0.9 - 1.2 mm) MIG wire, short circuit transfer on most applications is found in the weld current range of approx. 80 to 190 amps.

Optimum short circuit transfer with the most suited MIG wire diameter, 0.035 (0.9mm) is typically found between 100 and 180 amps with a voltage range 15 to 18 weld volts.

On the applications that utilize the 0.035 wires and the optimum short circuit current range, pulsed MIG using an 0.045 wire with can also be used with similar or slightly higher weld deposition rates.

In contrast to the "arc on - arc off", short circuit transfer mode, the pulsed mode is an "open arc" mode that delivers the droplets across the arc in a consistent transfer, that is if you have purchased one of the rare pulsed power sources that actually works in a consistent manner. In contrast to short circuit transfer set at 150 amps, the OPEN ARC pulsed process set at 150 amps delivers a hotter process.

Note If you were producing manual or robot short circuit welds at 180 amps and you want to try an 0.045 and the pulsed process, I would start the pulsed weld at 160 amps, then adjust.

Weld Fact: Using traditional MIG CV equipment: If you could get your hands on the 0.040 (1.1 mm) wire it would be the most practical choice for most "robot" short circuit and low current spray carbon and stainless applications in the 1.5 to 5 mm range. The worlds best wire for regular MIG equipment and gauge application is rarely used, this is no surprise in an industry that has never been able to implement Best Weld Practices.

WHAT'S BEST FOR THE WELDING INDUSTRY
IS OFTEN THE LEAST UTILIZED:

March 2001.
Weld Question: Ed. Why is the 0.040 (1.1 mm) carbon steel MIG wire such a good choice for gauge, short circuit and low spray parameter applications, and why is it so difficult to get?

In North America, Lincoln Electric is in a monopoly position in the MIG wire business. Lincoln does make small quantities of the 0.040 carbon steel MIG wire, however as Lincoln typically has had a hard time keeping up with the demand for it's traditional 0.035 - 0.045 steel wire products they are not exited about the 040 wire. It's understandable that from their perspective, that without extensive customer demand which would come from their marketing efforts and process educated consumers, there was little incentive for them to market the 0.040 wires.


[] If you cannot use 0.040 wire, the optimum weld wire for thin gauge current is the 0.035 wire which typically uses a working weld current of approx. 100 to 180 amps.

[] The "optimum" short circuit weld current for the 0.045 wire is approx. 170 - 200 amps. In contrast to the 0.035 or 0.040 wires, the 0.045 (1.2 mm) wire operates in a narrow, short circuit wire feed range that delivers higher weld current, thus being less suited to thin gauge parts (<2mm) and on these parts this wire will increase the weld burn-through potential.

[] For the 0.040 wire, the optimum short circuit current is approx. 130 - 190 amps. This current range is well suited to short circuit weld the very common and 14 - 18 gauge carbon steel and stainless applications. In contrast to the 0.035 wires, with short circuit and the 0.040 wire, you can expect slightly higher weld deposition rates and improved wire feedability which is very beneficial on robot gauge applications. The 0.040 wire needs less current to get into spray than the 0.045 wire making it especially suited to 3 to 6 mm spray applications.

THE US EXHAUST COMPANY THAT WELDED
ALL IT'S PARTS WITH STRAIGHT POLARITY.

Only in America!

Question: Ed can you describe the difference between straight and reverse polarity in MIG welding?.

Answer: As we can all likely do with some humor in our lives, I thought, rather than answer this common weld question in the traditional manner, that I would tell you about a welding application I was involved in a few years ago.

A Midwest company that supplies exhaust systems to the after market had major MIG welding problems. The owner of the company asked if I would visit his plant and report on the welding issues. He told me that some of his customers were complaining that the carbon steel welded flanges were falling of the exhausts during delivery.

I arrived at the exhaust manufacturing plant just before lunch. Like many automotive companies, the plant could not afford an $8 an hour receptionist and no one answered the lobby phone. To get access to the plant, I walked around to the back door. I entered the plant in the weld shop area and my welding senses went immediately on high alert. The "weld sounds" I heard from the approx. 40 MIG weld booths were unique, but I had heard them before. I heard a grunt from behind or it could have been a muted fart and as I turned around I saw what could only be called a Englisman's nightmare. Follow this link for the rest of this Mig Welding story

The bottom line on weld products and
"Supply and Demand".

A frequent weld management's solution to robot weld problems, when
you have robot weld productivity issues, order more robots.

Weld Fact: When the unqualified manager or engineers ask the unqualified welders who have skills but minimal weld process expertise, to try out that new weld wire or gas or power source, is it any surprise when the welders don't like the product?

<2006: At least fifty percent of the robots installed in North America are using a welding wire diameter or weld transfer mode which impedes the weld production or quality potential.

• 0.040 ROBOTS AND WELD WIRE BENEFITS: For short circuit or thin applications, with enough volume sold, the 0.040 MIG wire should "cost less" than an 0.035 wire, (larger wires typically cost less than smaller due to less wire drawing requirements)
  
  The 0.040 wire would have "less wire feed issues" than 0.035.
  
  

  In contrast to the 0.035 wire, the 0.040 short circuit "weld deposition rate" potential would be increased resulting in more manual weld deposited or faster robot weld travel speeds.
  
  The 0.040 wire is better suited than the 0.035 and 0.045 wires for welding "spray transfer on thin applications especially < 6mm. On these applications the 0.040 wire would enable higher weld deposition rates than the 0.035, and in contrast to the 0.045 wire used on spray applications, the 0.040 wire which requires less spray current would have less weld burn-through, less distortion and less undercut potential. Withe robots this wire would also result in less arc starting problems.
  
  
  
  Lets see, Ed is saying that if we are worried about weld quality and productivity, management and engineers should take ownership and responsibility for understanding the weld wire selection. Boy in this company that would be a first. Perhaps it's time I read his book on weld process controls.
  
  
  
  METAL GAUGE THICKNESS AND MIG GAS MIXES:

• The MIG gas influence on the short circuit steel weld arc stability and weld energy should be a primary consideration in MIG gas selection. For welding thin gauge carbon steels less than <0.060 "weld burn through" is always a primary issue.
  For welding thin gauge <0.060 steel applications consider a low energy, two part gas mix like an argon mix with 10% CO2 for carbon steels and a gas mix I developed argon - 2% CO2 for stainless gauge parts. For MIG information without sales bias, visit the MIG welding gas section.
  
  
  If you use three part gas mixes for any carbon steels or stainless applications, you are not using weld process logic, you are using the advice of a weld gas salesman.
  

Let's see, we have another important step for weld process control. When it comes to MIG gas selection we don't need to try a different MIG gas six times a year. We don't need the advice of a gas salesman and we should get rid of those costly, useless three part gas mixes. The bottom line is all our steel and stainless MIG welds can be made with a couple of simple argon CO2 gas mixes found in the MIG gas section at this site.

IT'S A FUNDAMENTAL FACT, THAT IF PULSED MIG EQUIPMENT WAS NOT
AVAILABLE TO THE GLOBAL WELD SHOPS, IT WOULD HAVE NO IMPACT ON
THE INDUSTRIES THAT WELD CARBON STEELS AND STAINLESS.

WELD QUALITY & WELD PRODUCTIVITY SHOULD NEVER BE AN ISSUE WITH LOW COST, CV MIG EQUIPMENT: The weld process mode you select will depend on the weld equipment and consumables in the shop. With low cost CV equipment, the short circuit, spray or controlled globular selected can produce, spatter free, perfect welds on most steel application, that is if the welders have the ability to set optimum MIG welds without playing around with the weld parameters.

With a traditional US. MIG power source at $2000 to $3000 range and pulsed MIG equipment in the $6000 to $12,000 range, the wise weld decision maker would place their focus on ensuring their weld personnel receive process control training, that will enable the weld personnel to have the ability to fully utilize and optimize the performance of the much lower cost CV equipment.

"PLAYING AROUND" DOES NOT GO WELL WITH
BEST PRACTICES OR PROCESS CONTROLS.

2006:For five decades, emphasis in the welding industry has been on welding skills, rather than on weld process expertise. This is a prime reason why most manual welders still"play around" with their MIG weld controls and the robots fill up the weld rework baskets.


IN AN INDUSTRY THAT PLACES FOCUS ON "SKILLS" AND MINIMAL FOCUS ON PROCESS EXPERTISE, IT'S TIME FOR SOMEONE IN THE WELD SHOP TO STEP UP TO THE PLATE AND FULLY COMPREHEND THE PROCESSES THEY USE.

2008: Note the typical wire feed control (current control) on this common MIG wire feeder. Miller,Hobart, Lincoln and ESAB have made wire feed controls for more than 5 decades, yet in 2008 not one wire feed control provides information to the welder on the selection of optimum MIG weld parameters.

You can be sure each day that thousands of welders around the globe will play around with a wire feed control like this and end up placing a scratch or pen mark on the feeder.

ED DEVELOPED A UNIQUE MIG / FCAW PROCESS CONTROL TRAINING METHOD CALLED THE "CLOCK METHOD".

The clock method is based on the fact that traditional, none digital wire feeders deliver a wire feed rate of 600 to 800 in./min (15 to 20 m/min). The majority of global wire feeders have provided this wire feed range since the development of the MIG process.

As with any training method, effective MIG process control teaching and training methods should always look for the common weld denominators in the operating or weld parameter requirements.
Lets start out with MIG welding and make the average, global wire feed rate for a typical MIG "none digital" wire feeder, approx. 700 in./min.

Ed developed the MIG Clock Method over three decades. The weld parameter Clock Method simplifies weld parameter selection for any carbon steel or stainless application and brings together the relationship between none digital and digital MIG wire feed settings, the application thickness, weld size and weld deposition rates.

Most wire feeders will deliver approximately 700 in./min. With the ten wire feed settings, starting at 7 o'clock and finishing at 5 o'clock, each turn on the wire feed control would therefore deliver approx. 70 inch/min per-turn. When you place the wire feed at the middle, 12 o'clock wire feed position, this is the fifth turn. 5 x 70 = 350 inch/min.

While Panasonic and other pulsed MIG equipment manufacturers inform the weld industry that their MIG equipment offers millions of wave form options, it's important the weld shop understands there are only three" optimum wire feed settings" for each weld transfer mode utilized.

Ed's Clock Method: With an 0.035 (1mm) wire, the majority of optimum carbon steel and stainless gauge welds will be made with short circuit settings found between the 10 and 12 o'clock wire feed positions. Set the wire feed control at the third setting which is 10 o'clock = 3 x 70 ipm = approx. 210 ipm.

At 10 o'clock, this short circuit wire feed setting delivers approx. 140 to 150 amp. This current is ideal for all manual carbon steel and stainless common gage sizes 0.050 - 0.060 (16 gauge) applications. Set the weld voltage at 17 volts and when training the welders, simply tell the welder to remember a great start point for all carbon steel and stainless sheet metal MIG welds, is 10 o'clock. with 17 cups of coffee.

USING TRADITIONAL CV AND PULSED MIG EQUIPMENT? There are 3 easy to remember, optimum wire feed settings for every MIG weld transfer mode and and 3 settings for any flux cored wire irrespective of the application. Want to learn them?

Ed's Weld Clock Method is applicable
to all digital feeders and robot settings.

Robots and time and weld gas influence on arc starts. At robot weld starts, it's critical for "consistent arc starts" to have the weld gas flowing before the arc is initiated. Poor arc starts occur if there is not sufficient gas, remember, its the arc plasma "ionized gas" which is the conductor for the transfer of electrons across an arc gap.

A robot offers many timed functions that a manual welder does not have to deal with. Arc ignition times, arc delay and crater fill times etc. With many robots, the different arc timed functions can accumulate. The arc ignition time may combine with the gas pre-flow time which may combine with the time in which the robot examines the arc ignition before it allows the weld to commence. The accumulation of start function times can result in the robot being stationary too long at the weld start. This is frequently evident in automotive plants when welding thin gauge and the weld size at the weld start is twice as big as the rest of the weld. The bottom line is the with thin gauge welds only use robot times at the arc start if weld start issues occur. Arc start data becomes much more relevant on parts > 3 mm

ROBOTS REQUIRE UNIQUE CONSIDERATIONS FOR WELDING gauge APPLICATIONS. ED'S ROBOT PROCESS TRAINING CD PROVIDES ALL THE SOLUTIONS AND THE ROBOT WELD DATA NECESSARY TO OPTIMIZE ALL CARBON STEELS AND STAINLESS ROBOT WELD QUALITY AND PRODUCTIVITY.

To see the worlds best weld process for gage welds check out TIP TIG:

MIG WELDING COSTS?

In many welding shops there is often greater concern for the cost of the welding wire or gas, than there is for the cost of the weld.

The objective of a MIG weld decision maker should be simple. Every time the welder presses the trigger on their gun ensure the settings wil deliver the desired weld quality with wire feed control set as high as possible.

Placing focus on attainable optimum wire feed (weld deposition rates) for a specific application, is achieved through process control education.

Weld Question: Ed. How does the welder know how much weld, they or a robot will deposit when using the 0.035 (1 mm) wire?

Answer: Its simple. With my unique clock teaching method. For each turn on a traditional wire feeder, the welder feeding the 0.035 wire at 70 in./min, delivers approximately 1 lb/hr (0.5 kg/hr) per-turn. So with the 0.035 set at the 10 o'clock (210 inch/min) short circuit position, the 10 o'clock setting is the third turn and this provides approx. 3 lb/hr. The robot arc on time per-hr is 20 minutes, so the robot deposits a one pound of wire each hour.

Any MIG or flux cored wire and any weld application. Once Ed's weld process training is provided, weld quality and production objectives are fully understood and Weld Cost Calculations are Made Simple.

You can attain your complex weld cost calculation tables from your weld equipment or consumable suppliers who are typically ready to pull anything out of their hats to get your weld equipment and consumable business. Or deal in Ed's world and use a very easy method to control your weld costs.

Let's see all I have to do to control welding costs is provide the weld personnel with Ed's self teaching MIG process control books, or provide this organization with process training with the Process Control training Program. These resources will keep the the weld focus on wire feed and deposition rates using the easy to remember weld cost clock method. Then I should make sure my engineers, technicians and supervisors keep their eyes on the wire feed settings used daily in the shop. Well now, that's worth looking into.

Weld Process Optimization can be this simple.
A good short circuit weld start point is,

17 CUPS OF COFFEE AT 10 o'clock.

Weld Question: Ed. How do I know if the traditional none digital wire feeder we use delivers the traditional wire feed range of 650 to 750 in./min (16.5 to 19 m/min)?

Answer: Every person who has to use a wire feeder that they have never used before would benefit from the following especially if you go for a job and are required to use a wire feeder you have never seen before. Also this simple test will let you know if your wire feeder is working correctly.

1. Set the wire feed control at the "12 o'clock position"
   Set a digital feeder at 350 inch/min
   
   
2. Press the gun trigger for 10 seconds you should have approximately 60 inches (1.5 m) of weld wire. Place one end of the wire under your foot and the other end should come to the top of the average size guy's chest.
   
   

How can an industry that has 50 years of MIG process expertise, hand out to the welders in it's facility contact tips that are the no thicker than the end of a pen and nozzles so small that they become blocked in minutes.

Many of the plants that I have been in that welded gauge metals, provided their employees with ridiculous thin (3 mm) OD contact tips and a nozzle diameter ID of approx. 8-9 mm. The MIG gun nozzle ID was so small (left) that after five minutes of weld time the nozzle is blocked with spatter or the contact tip will have shorted to the nozzle interfering with the current flow.

In one last plant I visited, the welders in the plant did not seem to mind the ridiculous consumables they were given as changing the tips and cleaning the nozzle was more comfortable than doing the actual welds. Of course it's logical to use a small diameter nozzles when you cannot get a standard nozzle as shown in the right photo into the required weld space. I am aware that the restricted welds will sometimes be necessary however for most MIG applications standard tip and nozzles are essential to the sucess of the weld.

The other amazing thing is once a poor practice like the innapropriate selection of the gun tips and nozzles are in place, the weld personnel will often not want to change to the correct consumables because "this is the way we have always done it"


The value of a weld is based on the wages paid the employee, the costs of the welding equipment and consumables utilized, and of course in the weld deposition rates attained. Combine those costs and in the USA you may have an annual cost per-welder between $40,000 and and a $60,000. Without the correct $2 contact tip to transfer the current in a stable manner and a $8 nozzle that allows the MIG gas to the weld, how much of your weld costs do you believe go flying out of the window every day?


Understanding the weld tools we work with, now that will be a first for our weld shop. I suppose in reality this is simply another logical step in weld process control. Let's face it, we either control the bloody weld process or let the process and the salesman control us.

Question. Ed where do we position the contact tip for manual or robot short circuit welds?

Answer.To use the lowest voltage for thin gauge parts which typically is required for short circuit welding <16 gauge, stick the contact tip outside the nozzle 2- 3 mm. Welding short circuit on >16 gauge, place the contact tip flush with the nozzle.

Question. Ed, we short circuit 0.035 (1 mm) hydro formed gauge parts. On the seam welds, the lap joints open up between the robot fixture hold points. We always end up burning through at this area, any suggestions.

Answer: Use a manual welder or the robot to MIG spot weld the areas subject to problems. Don't know how to set a MIG spot weld, it's in my books.

Any manual MIG welder or robot can become a MIG spot welder. You need no special equipment, just a little technique and a little process knowledge that's found in my books. You can MIG spot weld any steel stainless, aluminum or alloy gauge applications.

Weld Question: Ed, as most of the wire feeders sold today provide a digital wire feed rate why bother with the clock method?

Answer: The Clock Method "simplifies" weld parameter selection and its extremely easy to remember any weld setting for all MIG and flux cored weld applications.

Digital or none digital when you learn the clock method you end up with the ability to instantly set any manual or automated weld without playing with the weld controls or parameters.

Please remember the traditional, low cost, more durable none digital wire feeders can last 10 to 20 years in a welding shop, and in 2007, there are over a million traditional wire feeders out there. As a weld decision maker you will most likely have to work with these common durable wire feeders. If you are a professional at your craft you should know how to set that simple one knob wire feed control, rather than "play around" with the controls. If you are a trainer this method is easy to remember, therefore it's easy to teach.

When you combine the optimum weld volts with the optimum wire feed, the optimum short circuit welding parameters will produce a crisp, consistent, rapid crackle sound.

The Sweet Sounds of MIG: Today the majority of MIG welders, use arc sounds as a method of fine tuning their weld parameters. The weld reality, both welders and robot operators should know "the cause of arc sounds" and the "correct weld parameter weld control response" to those arc sounds".

The sweet spot or sweet sounds attained with short circuit transfer result when the recommended optimum wire feed and voltage parameters are used. The optimum weld current (wire feed rate) and weld voltage will result in the maximum amount of short circuits achieved each second. The more rapid the short circuit crackle sound the more consistent the "spatter free" weld transfer.

DUE TO LACK OF WELD PROCESS EXPERTISE,
WELD SPATTER COSTS MILLIONS DAILY:

The welding industry spends millions daily on cleaning welding spatter from its parts. The welding equipment manufactures even build special electronic MIG power sources designed to produce minimum weld spatter. The weld reality is this. For the majority of gauge applications, when welding with a low cost, durable, easy to use and easy to repair Lincoln, Miller, ESAB, or Hobart 200-400 amp, CV power source, as this 20 year old video show, set the correct short circuit or spray welding parameters and you will attain minimal weld spatter.

Weld Fact: Remember the key to minimizing short circuit weld spatter is to keep the short circuit weld drop as small as possible and create the fastest rate of short circuit weld transfer. This is achieved working in the recommended SC wire feed range, and ensuring the weld voltage is set to it's minimum.

You don't need to invest in a sophisticated Fronius CMT, Lincoln STT or a Miller RMD electronic power source to control weld spatter, you simply use a traditional low cost durable, low cost CV power source and teach the welders or robot personnel to set the correct weld parameters. Most weld spatter occurs with short circuit transfer from a traditional CV power source because the welder has set their weld volts too high.

Your self taught welders may have 20 years of skills experience, however please remember "welding skills are not weld process control expertise" Instead of investing in costly, unnecessary weld equipment which may be impossible for your electricians to repair, or buying loads of anti-spatter, surely its more logical to provide your welders with some process control training.

LETS SEE WE HAVE BEEN BUYING ANTI-SPATTER COMPOUNDS FOR TEN YEARS, AND WE ARE NOW LOOKING AT VERY EXPENSIVE ELECTRONIC MIG WELD EQUIPMENT. WHY WITH A LITTLE WELD PROCESS KNOWLEDGE MY WELDERS COULD STOP PUTTING THAT COSTLY OIL AND WATER ON THE PARTS AND WITH THE MONEY I SAVE, I COULD TRY THAT MINOXIL AND GET SOME HAIR GROWING BACK ON THIS BUSY HEAD.

This picture proudly presented in a USA welding magazine, shows newly trained, Detroit MIG welders welding a truck frame. The worst MIG welds found in the industrial world are found on in auto / truck frame plants. The excessive weld sparks seen in the picture, indicate poorly tuned manual MIG welds as evident by the fire works display. The amount of weld spatter generated is excessive and it's evident excessive wire stick outs are being used.

These welders in the photo were trained by a national auto training organization based in Detroit, it's purpose to help auto companies with their weld issues. Obviously the trainers at this Michigan organization placed little emphasis on teaching weld process control.

It's a sad reality also that whenever you find bad manual MIG welds, in the same plant you are sure to find bad robot MIG welds.

A Self Teaching, Weld Process Control resource for less than $400 may be the
smallest investment we ever make with the largest return.

How many companies are prepared to invest a few pennies per supervisor, robot personnel or welders, for weld process control educational resources or a training program designed to optimize both the manual or robot welding in their organization?

Shoot, it seems the biggest impediment to the implementation of effective Weld Best Practices and Process Controls in my plant is the face that stares back from my mirror.

Most of you reading this weld data will be aware that the welding personnel at your facility are not aware of all of the weld data presented at this site. I have a question for the you, how important is it to your organization to attain MIG or flux cored manual or robot weld process controls? If you think you don't need this type of weld data, do me a favor and try the MIG welding Spray Transfer quiz, and then ask your self how important is this MIG data to your organization

Consider how easy it is with this unique clock method to bring your weld personnel into a lunch room put my CD in your lap top and project weld data that will optimize the MIG or flux cored welds. Reduce your product liability and eliminate weld rework. Get instant control of your weld costs through optimum weld deposition rates. Get your weld shop into a professional mode with management and weld personnel all walking the same path providing consistent, daily uniform weld results. Become a weld shop that frowns on individuals that play around with the process parameter controls.

HOW YOU CAN USE THE CLOCK METHOD FOR OTHER COMMON WIRES. Welding pipes or structural steels? Do you know the optimum welding parameter range settings for an 0.045 (1.2mm) Alloy Rod E71T-1 flux cored wire, for welding a 1/4 (6mm) fillet weld in the vertical up or over head positions?. What's the single optimum setting for that 1/16 (1.6 mm) flux cored wire? With the clock method its simple and of course flux cored is covered in my books.

TIP TIG 409 16 GAGE SEAM WELDS.	TIP TIG 409 16 GAGE SEAM WELDS
IF VIDEO PAUSES PLAY A SECOND TIME If you compared short circuit or pulsed MIG with this TIP TIG seam weld or any other steel or alloy seam gauge welds, you would instantly note the superior weld quality from TIP TIG. While the MIG welds may have fume concerns, oxide formation, spatter, distortion and possibly require manual cleaning or weld rework, in contrast the TIP TIG welds would not create these common weld production issues.	Customer wanted to see the quality and production capability for TIP TIG on this seam application. The automated set up was easy, just attach the TIP TIG torch to the auto carriage. No sophisticated equipment required like complex plasma or Arc Volt Controls. Within 10 minutes the TIP TIG was producing the parts shown on the left. With automated TIP TIG seam gage welds such as this, you can anticipate the welds would be made between 25 - 35 inch/min. (500 to 700% quicker than manual TIG)

For more TIP TIG data on the patent pending TIP TIG weld process
contact Ed Craig USA. Eastern Time. 828 658 3574.
E-Mail ed@tiptigusa.com or Tom O'Malley tom@tiptigusa.com.

To find out more on controlling manual and robot gage welds, MIG short circuit,
spray, pulsed MIG or flux cored, click on "Ed's Training Resources.