IN THE LAST 60 YEARS THAT I HAVE BEEN IN THE WELD INDUSTRY, I PROVIDED WELD PROCESS INMPOVEMENTS  IN 13  COUNTRIES, AND  THE MOST IMPORTANT FACTORS  THAT I HAVE SEEN INFLUENCE WELD QUALITY AND PRODUCTIVITY, HAS BEEN THE  GLOBAL, LACK OF FRONT OFFICE WELD PROCESS OWNERSHIP, AND  ALSO THE WELD SHOP FLOOR LACK OF WELD PROCESS CONTROLS AND BEST WELD PRACTICE  EXPERTISE.

NOTE:  WELD SHOP PROCESS CONTROLS HAS NOTHING TO FO WITH WELD SKILLS,

It’s a reflection of the general lack of  front office  weld shop management  and with the weld shop floor supervision, that  in this “why change the way we have always done it industry, that sixty plus years after the introduction of the semi-automated GMAW and flux cored weld processes, that few weld decision makers  know how to implement  Weld Process Controls and Best Weld Practices. Its also a weld reality that  with these weld processes that the majority of global  weld personnel will “play around”  with the  two simple weld controls on their  weld  equipment.

In the diverse industries in which welding plays a key role, weld rework, and costly weld rejects are common, however it’s not just weld quality, on most weld applications, its also rare to see maximum weld deposition rates being attained, even more  uncommon is to find someone that truly understands  weld costs. I suppose this is understandable 

“WHY CHANGE THE WAY WE HAVE ALWALYS DONE IT, AND  GIVE ME A MINUTE TO PLAY WITH THE CONTROLS”  COULD  BE PUT TO MUSIC AND  MADE INTO THE GLOBAL WELD SHOP ANTHEM.

It’s a sad reality in 2021 North America, that in many of the CODE WELD QUALITY industries such as defense, aerospace, power  and medical, that thirteen years after I introduced TIP TIG to North America and Australia,  that TIP TIG which is an  improved version of TIG, that few of code weld shops are aware of the dramatic weld  part quality, and  weld cost benefits obtained from the simple to use, TIP TIG weld process.

ELON’S LACK OF ROBOT WELD PROCESS OWNERSHIP  AT TESLA COULD HAVE TAKEN MUSK TO BANKRUPCY,  SO THEN WHEN  ELON HIRED ENGINEERS FOR SPACEX,  HE SIMPLY WAS NOT AWARE OF THE REQUIRED LEVELS OF  C0DE WELD PROCESS CONTROL EXPERTISE, AND THAT LACK OF EXPERTISE SOON BECAME EVIDENT WITH THE ENGINEERS  NASA. 

In late 2019, as SPACEX struggled to prove it could weld rockets that would pass NASA destructive tests, one of  Elon’s engineers finally figured out that to consistently attain the ROCKET destructive stainless  weld tests required by NASA, that SPACEX would for their rocket arc welds have to use the TIP TIG process, a process that ironically I had introduced to SpaceX engineers at a Philadelphia TIP TIG work shop way back in 2009.

ITS’ ONE THING IN ENGINEERING TO BE IGNORANT DUE TO A PERSONS APATHETIC NATURE IN WHICH ONE DOES NOT KEEP UP WITH THE TECHNOLOY THAT PAYS THEIR MORTGAGE,  IT’S ANOTHER THING FOR ENGINEERS AND MANAGERS NOT TO UTILIZE THE EQUIP, AND PROCESSES  INFORMATION THAT WAS HANDED TO THEM ON A SILVER PLATE.

I developed a web site that provides all the real world weld knowledge on TIP TIG,  https://tiptigwelding.com, This site shows in contrast to any other arc weld process, the  Semi-automated or Automated TIP TIG weld process will  provide superior weld quality than any other available, manual, arc weld process, and that includes GTA and Hot Wire GTA.

TIP TIG is a process that should finally enable the elimination of weld rework. TIP TIG while providing the highest weld energy in an inert atmosphere is unique in that it also produces the lowest welded part heat input which enable with any metals,  the best possible mechanical and corrosion properties, the highest sensitivity to cracking with the lowest possible distortion. TIP TIG is also a  weld process that reduces all position, pipe, root / fill pass welder skills, it can eliminate weld cleaning,  plus no weld spatter or weld fume concerns. The benefits of  the TIP TIG process on CODE quality steels and  alloy weld applications are extraordinary, and just as extraordinary has been the slow global weld industry  response to the  extensive quality / cost benefits that could be attained.    

In 2009, when I bought TIP TIG to N America, I was aware that this process was simply the evolution of the 75 year old GTAW weld processes into a semi-automated or fully automated process, and TIP TIG would provide something  that for decades has been unattainable, the  ability to consistently produce the highest energy welds with the lowest possible weld heat input.

TIP TIG the easiest to use in any weld position.. No smoke. No spatter. No weld cleaning required. One process for all code quality welds and only two weld settings required  for all welds. Suited to metal type or thickness. Why would any weld shop consider the inferior GTAW – Pulsed MIG and Gas Shielded Flux Cored weld processes for their code quality welds? For the worlds most informative web site on TIP TIG without sales influence, visit my other web site, https://tiptigwelding.com

_________________________

It  only takes a 30 minute demonstration for a weld shop to view the following TIP TIG weld benefits for code quality welds .

• TIP TIG enables  200 to 400% greater weld deposition than TIG.
• TIP TIG on all position welds is easier to use than  DC TIG, Pulsed MIG and Flux Cored, while always producing superior weld quality.
• TIP TIG with increased weld speeds and DC polarity always enables superior  mechanical / corrosion properties obtained than any other arc weld process.
• TIP TIG always enables the lowest possible weld fumes.
• TIP TIG no weld spatter, and no weld cleaning required.
• TIP TIG always lowest weld distortion and lowest weld / part stresses.
• TIP TIG highest weld fusion capability with no weld porosity concerns. 
• Use TIP TIG on large or small applications, one process root to fill, one process capable of welding all metals from  the thinnest to the thickest parts.
• TIP TIG semi-automated or easily fully automated.
• TIP TIG, one gas, one weld wire, no more than three simple weld settings and one weld procedure.

____________________

IT’S UNFORTUNATE IN N. AMERICA THAT THE INDUSTRIES AND RESEARCH FACILITIES THAT SHOULD LEAD IN WELDING, ARE TOO OFTEN THE ONES STUCK IN THE 20th CENTURY.

There is extensive evidence at this site of the the common lack of front office weld process ownership, and slow weld process evolution that prevails especially in the high tech. industries that should lead, industries such as the  Aerospace, Defense, Medical, Oil, and the Power industries.

Getting a Navy shipyard that will typically spend annually hundreds of millions on over budget weld rework or poor weld productivity to change it’s sad engineering / management approach to arc weld quality and productivity, would be a  rare event when the most common lament at the weekly weld meetings, will be “why change the way we have always done it”.  In the same ship yard, most of the  highly trained welders will do  as most welders have done for more than 60 years, “play around” with weld controls. These are simple controls on MIG equipment that’s  changed little in decades. The end result will always be  poor weld quality and productivity.

 I  will always wonder why after I introduced TIP TIG to SpaceX engineers at  a seminar and hands on workshop that I provided in the Philadelphia Naval Yard  around 2008 -9,  that it then took their engineers and managers approx. a decade to figure out  the value of this important arc weld process. Of course I know the answer,  but I am to polite to provide it here. And even with extensive use of TIP TIG now in 2020, I believe that Musk and his SpaceX engineers are still not aware of the full manual and automated weld application capability and potential of this important process. It’s notable in 2020 in a weld engineers job description for the SpaceX facility in Texas, that this process was not included in the weld engineers job description.

All mechanical and weld Engineers have a responsibility to always ensure that they  evolve to weld processes that will produce superior weld quality with lower weld costs.

WELDING ENGINEERING APATHY IN THE USA, HAS ENABLED THE CHINESE OIL INDUSTRY  TO ATTAIN WELD QUALITY / PRODUCTIVITY SIMPLY NOT POSSIBLE IN THE MAJORITY OF WELD SHOPS THAT SERVE THE OIL INDUSTRY IN N.AMERICA.

At the same 2008 – 9  workshop that I  introduced  TIP TIG to the SpaceX engineers, there were also five engineers from CNOOCA, one of the largest Sub Sea oil companies in China.  Instead of ten years for this company to embrace the TIP TIG process  it took them  a week of watching myself and  my partner  Tom weld, weld and weld with the TIP TIG process. Then it took a month for this company  to make TIP TIG  their companies prime manual and automated weld process to be used for the majority of  their code quality welds  welds on their  Subsea, Oil – Nat Gas and LNG fabrication business.

Lack of  weld process “ownership” from managers and engineers, has lead to the majority of high tech companies that are faced with  21st Century code weld challenges, to keep on using 20th Century weld processes, along with outdated weld specifications, procedures and practices. In the global, highly competitive world of metal fabrication, if companies don’t look for or resist  progressive weld process changes that can create weld quality, productivity and cost improvements,  they may as well  close their weld shop doors, and open up a coffee shop. For those that want the most comprehensive information on  TIP TIG, visit my other web site, https://tiptigwelding.com 

_____________________

A weld reality in 2020 for those industries in which traditional  Pulsed MIG, GTAW and gas shielded flux cored welds are important

• The daily weld quality and weld production produced will often have changed  little in six decades.
• Weld rejects and weld rework is expected.
• Weld spatter and weld cleaning are the norm.
• Many times more than one weld process will be used on the job that requires different procedures, equipment, consumables, practices and skills.
• In the weld shop front offices, there will is usually little evidence of  the Weld Process Ownership capability that’s necessary for consistent process optimization.
• On the weld shop floors,  you often will find little evidence of “arc weld process controls and best weld practice expertise”
• It will be common to find experienced weld personnel that will  “play around” with their manual. automated or robot MIG and  flux cored weld controls. 
• In any company that has a weld department, It’s always difficult to find someone in their  front office who understands the process control requirements  necessary for weld process  ownership. It’s also near impossible to find someone who in less than five minutes could tell you the cost of a foot  of one of their common  1/14  MIG fillet welds.

________________

Lack of  global front office weld process ownership is a common  missing  link

My name is Emily Craig used to be Ed but a plasma cutter took care of that problem. From assisting Aerospace and Defense companies, to Shipyards, Nuclear or Automotive plants,  over a 40 plus year span, I was asked and still being asked by more than a 1000 weld shops in 13 countries to solve their manual and robot MIG – GTAW – Flux Cored – Hot Wire TIG, SAW and Plasma  weld  quality and productivity issues. 

I introduced this  weldreality.com site around 1998, and this site is an outlet that enables me to vent my frustrations and that I found with most of my  global weld experiences. The site also allows me to discuss my favorite subject, common global weld shop issues, and more important, provide to those that are not influenced by salesmen, practical, cost effective weld resolutions.

ONE SAD ASPECT OF THE GENERAL GLOBAL WELD INDUSTRY. IS THAT IT FOCUSES ON IDENTIFYING WELD DEFECTS, RATHER THAN ON PROVIDING EMPLOYEES WITH THE PROCESS CONTROL EXPERTISE NECESSARY  TO  “PREVENT WELD DEFECTS”. 

For decades, in diverse industries such as Shipyards and Automotive plants, many in weld management think it’s the norm to annually spend thousands or millions of dollars on weld rework, weld rejects, and also pay a price for  poor weld productivity?  It’s been my weld reality, that most managers and supervisors put more emphasis on the qualifications of their weld inspection personnel than on the weld process expertise than can prevent weld issues.  Whats the use of a qualified AWS weld inspector if they don’t know the weld process controls and best weld practices that are necessary fo weld optimization.

Eventually when managers or engineers realize that their costly QA department  and weld personnel are not  providing  effective weld process resolutions to the daily manual or robot weld issues, the manager may then turn to more expensive weld resolutions such as, employing more welders,  purchasing more robots,  adding manual welders to robot cells, or as common with the N.American automotive industry, outsource the welded parts to the southern States  that pay lower wages, or better still to Mexico which pays even less. Or perhaps they may instead invite the local weld sales rep to talk about their  distributors latest, overpriced pulsed weld equipment, that in many instances will be is loaded with useless electronic bells and whistles. And if  the purchase of new weld equipment does not work, the management could consider another crutch,  such as the purchase of another useless three part gas mix, or an expensive metal cored weld wire. The sad weld reality for global weld decision makers that have a difficult time consistently attaining the full manual or robot weld quality and productivity potential from the world’s most utilized arc weld processes  MIG, Flux Cored and GTAW, is that for decades, daily producing  mediocre weld quality and productivity, and creating unnecessary  costly weld rework has become the NORM.

_____________________

MOST MANAGERS ARE NOT AWARE THAT WELDER SKILLS HAVE ALWAYS BEEN A SECONDARY REQUIREMENT FOR WELD PROCESS OPTIMIZATION:

MANAGEMENT WON’T  PROVIDE THE RESOLUTIONS IF THEY  ‘DON’T RECOGNIZE THE ROOT CAUSE OF THE PROBLEM:  An essential requirement for front office weld process ownership is for the companies key weld decision makers to understand the value of something that for decades few managers  or engineers are aware is an essential  requirement,  weld process controls – best weld practice expertise. With the lack of awareness this expertise  will be something that’s  rarely  required in  any weld job description. This is a subject that  I have studied for four decades, and since the introduction of arc weld processes, a qualified weld manager would be aware that it’s not the welder skills that are the most important attribute in the weld department, it’s the level of Weld  Process Controls and  Best Practice expertise that enables an organization to consistently attain  maximum, optimum utilization of  both the weld processes and weld consumables utilized. 

SURELY THIS IS NOT WHAT ENGINEERING IS ALL ABOUT: When the weld shop’s front office engineers, managers or supervisors have a weld process resolution they can’t resolve, they will often turn to their local sales rep. and in most instances this will be an individual  that  likely has never run a weld shop. The weld industry is the only technical industry that relies on  inexperienced sales or equipment  representatives to provide weld process advice for a shop’s weld issues, and these are issues that typically have been going on for decades, issues with weld equipment that typically has two weld controls.  As a corporate training or weld product manager at Linde,  Airgas, AGA and Carbonic, I put on simplified weld process control training programs  for close to four thousand N. American  weld sales personnel, and I came to a conclusion that  perhaps five in a  hundred had  a comprehensive understanding of  the typical weld equipment and consumables used in the weld shops they serviced.

One area that always  dramatically reveals the lack of MIG weld process controls and best weld practice expertise that prevails in most global automotive and  truck plants, will be found in the often poor, ever changing weld data, that has unfortunately has been provided into the robot pendants:

For gods sake, personnel “playing around”  with the weld control data in a robot cell, is not a sign of enlightened engineering and mfg. management. It’s  an indication that the company management is simply not aware of  the weld process control expertise that’s  required  by technicians and engineers to attain the best possible robot weld quality and productivity. 

LACK OF WELD PROCESS CONTROLS  & LACK OF BEST WELD PRACTICE  &  ALSO LACK OF WELD COST EXPERTISE IS SIMPLE TO RECTIFY:

If managers, engineers and supervisors in automotive and  truck facilities, don’t understand  the robot weld process control expertise requirements for weld process ownership, it’s not likely their robot technicians or those that are making the weld changes will  have this expertise. If a rare enlightened  plant or engineering manager had insisted that at least one person in their  plant had the weld process control and best weld practice expertise that’s necessary to optimize either the robot or manual  weld quality or productivity process performance,  that same manager, would also be wise enough to ensure that their weld process  control expert was  given the responsibility to train all those in both the front office and the weld shop that  daily are making the weld decisions.

Please be aware, that I spent decades condensing and simplifying  my manual and robot weld process control training resources so that irrespective of their weld background, they could be presented by anyone.  By the way, it’s only logical that every weld decision maker’s “Job Description”  should include the words, “Must have the required Weld Process Controls and Best Weld Practice expertise”.

THIS WILL SHOCK MANY. A “WELD TEAM” IN ANY MANUFACTURING FACILITY, IS TYPICALLY A SIGN OF “INEXPERIENCED WELD MANAGEMENT”.

THE WELD TEAM: Another unique attribute about poor global weld  shop practices, is when managers, supervisors or engineers lack weld process control and best practice expertise  they will frequently create a Weld Team, a team that ironically will also lack the same expertise.  The common manager’s response to their never ending weld issues is to daily take an acid reducing TUM to control their heart burn, and then  call a WELD TEAM meeting. Too often the only thing frequently achieved by the weld team will be  the consumption of a large amount of  coffee and donuts, wasted man hours, and more weld process confusion added to the plant. 

My easy to learn  manual and robot weld process controls and best practice self teaching or training programs typically only require 15 to 20 hours to learn.  If  this training was provided  to all  the company’s personnel that  daily influence weld decisions,  the weld reality  is that no plant or weld facility  would require  a”weld team” and the reason would be, that  all the companies weld decision makers would be trained with the weld process  control – best practice requirements that enable them to uniformly walk the one path required to consistently attain,  manual or robot weld process optimization. Think how unique that would be a plant in which all involved in weld decisions were trained in the requirements for weld process ownership.

Process OWNERSHIP comes from My MIG – Flux Cored  and TIP TIG,  Manual and Robot Weld Process Controls & Best Weld Practice, Training or Self Teaching Programs.

HOWEVER A MANUFACTURING TEAM IS LOGICAL. Rather than creating  a robot weld team, a more logical approach in an organization that understands weld processes would be to create a  “manufacturing team”. This would be a team comprised of the key robot weld decision maker, and the production, quality, maintenance and engineering manager. The manufacturing team’s prime responsibility would be to ensure  that the products for the robot cells should be delivered  in a timely manner, and the parts to be welded by the robots would be manufactured in accordance with the  specified design,  conditions and dimension,  (always a rare event in poorly managed auto / truck plants).

2020. In the weld shops that produce code quality welds in industries such as Power, Aerospace, Oil. Medical and Defense, you will find many stuck in the 20th Century.  And you will often find their weld departments encased in a  “this is way they have always done it”  mentality. Heads up folks, there is a ten year old weld process called TIP TIG, a process  that will enable weld shops to use this easy to use process and produce cost effective welds without the need for weld rework.

TIP TIG  is a process that my business partner Tom and I bought to North America and created our company called TIP TIG USA. We also introduced TIP TIG to Australia and China. The suitable weld applications for TIP TIG, and where  this process should be used rather  than using the  GTAW – Pulsed MIG, Flux Cored and Hot Wire TIG processes are discussed briefly on this page and the world’s most extensive TIP data is provided  in the TIP TIG section, and in my tiptigwelding.com web site available Feb. 2020. However I am well aware that on the subject of weld process changes and weld shop evolution, with  those weld shops that lack front office weld process ownership,  there will typically be a major common hurdle to overcome, and that will be the weld department’s attitude to change.

In a highly competitive industry, an experience weld shop manager, supervisor or engineer should never allow this attitude.

THE AGGRESSIVE RAPID ARC WELD PROCESS EVOLUTION THAT’S TAKING PLACE IN CHINA:  I am well aware of the reasons  that “CHANGE”  for many weld shops is difficult to implement, after all, lets face it, this is an industry that’s seen little progressive or cost effective arc welding process changes for steel and alloy steel welds in the last 60 years.  However  the 20th Century has passed, and in the North American welding industry there has never been a more important time for key weld decision makers to want to embrace cost effective, weld process changes, the reason is a simple one. China with 1.4 billion and India with 1.3 billion populations, have  in 2020, with their extensive weld labor cost  advantages also have the same manual and automated  arc weld equipment and consumables capability as any other country.  The weld reality is as you will see in the TIP TIG section and in my new web site https://tiptigwelding.com   is that in the aerospace, power, oil and defense sectors, that when it comes to manual and automated arc welding,  China (above two welders) is  already a decade head of N. America.

INSTEAD OF PURCHASING LOW COST DURABLE CV MIG EQUIPMENT,  MANAGERS WHO RELY ON WELD SALES ADVICE WILL OFTEN SPEND 200 to 300% MORE FOR PULSED MIG WELD EQUIPMENT FOR THEIR MOSTLY STEEL AND STAINLESS WELDS, THE QUESTION IS WHY? Of course electronics in MIG equipment has enabled interesting weld transfer mode opportunities especially with pulsed MIG aluminum welds.  However much of the electronics that from the 1980s to 2020, that have gone into pulsed MIG equipment that is used for steel and alloy welds, have in reality been  mostly useless BELLS & WHISTLES. 

FEW WELD SHOPS ARE AWARE OF THE NEGATIVE WELD QUALITY AND COST ATTRIBUTES OF PULSED MIG WELDS: Anyone who has ever done a weld macro on a steel or stainless fillet weld on steels > 5 mm thick, will be aware with the MIG Spray mode that unfortunately has a poor ratio of weld energy to weld mass, will view that the weld fusion attained  is  often poor to marginal. When that Spray mode is changed to a pulsed mode that can provide the same weld deposition potential as Spray, but however spends 50% of  its time at a low background current, then is should not be a surprise to find that this lower energy mode will in contrast to a Spray weld, not improve  the weld fusion or reduce the weld porosity, but that pulsed MIG mode will suitable for welds that require lower weld energy, welds on  gauge steels, aluminum,  and clad welds. I wrote  a book on MIG and Pulsed MIG over 20 years ago. That book was called “A Management and Engineers Guide To MIG”.In this book I dedicated over a 100 pages as to what was wrong with the pulsed MIG mode for steels and alloy welds, and all the issues I discussed then are still relevant today in 2020. By the way those weld shops that purchased costly  Pulsed MIG  equipment to reduce weld spatter, could have spent  $200 on one of my MIG training programs and eliminated their spatter concerns with something called Weld Process Control Expertise.

In the 1970 and 1980s, with low cost CV MIG equipment, I was showing weld shops how to produce MIG short circuit welds with no spatter.

THERE ARE TWO WAYS TO RUN A WELD SHOP.  ONE WITH WELD PROCESS OWNERSHIP CAPABILITY.  THE OTHER WITH THE ADVICE OF A WELD SALES REP.

In the nineteen sixties I  started  MIG and flux cored welding  tractors in a Massey Ferguson plant in Manchester England, and today in 2020 in any global weld shop, I could take a 1960s CV MIG power source, or a 2020 $2500 new CV MIG power source, and with MIG weld process control expertise, consistently provide optimum quality, spatter free welds on any steel  and alloy steel parts from 14 gauge to any thickness.  So the weld reality for the one or two readers that are aware of this 20 year old website,  is if the weld shop mostly welds aluminum parts that less than 6 mm thick,  then the purchase of a pulsed MIG power source provides many weld benefits. However if the weld shop welds thicker aluminum parts, the weld shop will attain better aluminum weld quality by using the CV spray mode on the lower cost CV MIG equip. If the weld shop welds mostly steels and alloys the weld shop will save money if it simply purchases  CV MIG units that can typically cost 100 to 200% less.   Think of the  savings for the weld shop from being able to purchase the lower cost, easier to repair, more durable CV equipment that has two simple weld controls and for the occasional aluminum welds provide a portable pulsed MIG unit. Weld decisions such as this, require managers and engineers that are capable of Weld  Process Ownership. Managers that will be  aware they can optimize their steel MIG and flux cored welds  with low cost CV MIG equipment because they have provided all their weld personnel with the required  MIG Weld Process Controls – Best Weld Practice Training. 

THE PURCHASE OF THREE PART GAS MIXES AND METAL CORED WIRES ARE ALSO  OFTEN INFLUENCED BY SALES  BOVINE FECAL MATTER:While some metal cored wires that contain alloys may be beneficial for high strength applications, when welding low carbon steels. I never saw a metal cored weld I could not replicate with a lower cost MIG wire. As for those three part MIG gas mixes, as a key writer of the AWS MIG Shielding Gas Specifications, I would like to inform any weld shop that over the last four decades purchased a three part MIG gas mix for steels and alloy steel welds, that the costly three part MIG gas mixes were never necessary and the reality of adding oxygen in a gas mix created more negative attributes to a weld than benefits. I will admit however that both the metal cored wires and three  part gas mixes were always a good tool for the weld distributors to attain gas business in weld shops that lacked the ability for MIG weld process ownership.

On many steel and alloy weld applications, for decades, the common useless electronics found in pulsed MIG equipment was a good companion for the useless three part MIG gas mixes and metal cored  wires that were also used as a crutch by those that lacked weld process control expertise.

GAS SHIELDED FLUX CORED: In 2020, the majority of global weld shops may also be surprised to hear that both GTAW and the Gas Shielded Flux Cored process  are  a poor weld process choice for many code quality welds.  For those using all position gas shielded flux cored wires in 2020 on applications that require X-Rays or Ultrasonic testing, a reasonable question would be why would any weld shop choose a weld process such as flux cored,  in which irrespective of the welder’s skills, unreliable weld quality, excess  porosity, trapped slag weld fusion concerns, excess spatter  and excess weld fumes will be the norm. 

ITS 2020 AND SOMEONE FORGOT TO TELL WELD SHOPS THAT IN THE LAST DECADE, THE GTAW PROCESS BECAME OBSOLETE: And If the weld shop is still using the seventy year old DC. TIG process  for welding parts that require an extensive amount of welds, what  manager has not been frustrated in dealing with this ultra slow process that requires the highest welder skills, and also provides high heat into the welded parts. Note: For those that are interested in the well documented  issues that occur with the common MIG –  Pulsed MIG – GTAW -Flux Cored processes and their equipment and consumable issues when utilized on  manual and robot welds, please visit my programs sections. While pulsed MIG,  DC TIG and the gas shielded Flux Cored processes have since the 1960’s,  been responsible for most of the  global code quality arc welds that are produced daily, in 2019, few weld shops are aware that for more than a decade there has been  an alternative,  superior, “manual semi-automated and fully automated” weld process called TIP TIG.

TIP TIG is  a process that  may appear at first glance for some weld personnel to be a cross between  the  TIG and MIG process. However this is a process that  when code quality welds are required, TIP TIG will provide superior weld performance than TIG – Pulsed MIG – Gas Shielded  Flux Cored and Hot Wire TIG welds.

TIP TIG is both an easy to use semi-automated and fully automated arc weld process. When code quality welds are required, by consistently enabling the highest weld energy in an inert atmosphere,  (best weld fusion lowest porosity) along with attaining the lowest welded part heat input from DC polarity and increased travel rates. In contrast to GTAW – Pulsed MIG – FCAW and Hot Wire TIG, the TIP TIG process will always attain the best possible weld quality and also part mechanical and corrosion properties.

___________________-

TIP TIG provides the highest weld energy and weld fluidity, with the highest weld purity, and also enables the lowest weld part heat with an easy to use  process for welds on any metals, applications any size, and welds in any position..

WHEN TOM MY BUSINESS PARTNER AND I  BOUGHT TIP TIG TO NORTH AMERICA  IN 2009 AND STARTED  “TIP TIG USA, THIS PROCESS CREATED DRAMATIC NEW WELD OPPORTUNITIES FOR WELD SHOPS IN  N.AMERICA,  AUSTRALIA AND CHINA.

2020. I predict that by 2025, the “Plasch Austria” patented TIP TIG process that I and my business partner Tom introduced to North America, China and Australia in 2009,  will be  the  world’s most widely utilized arc weld process that is associated with most code quality welds.

With so many weld, metallurgical, mechanical, corrosion, and  also weld fume safety benefits obtained from  TIP TIG,  benefits that are spelled out on this page and  especially in my comprehensive, “TIP TIG” program which provides TIP TIG data that’s not provided on any other global website.  For any weld shop the weld reality is this, when the highest possible quality on all position, root or fill, fillet or butt, small or large parts, on manual or automated applications are required, the weld shop will find TIP TIG will  be easier to use, (less skills), and always produce superior  weld quality than the traditional   DC/AC  TIG –  Pulsed MIG –  STT  MIG – RMD MIG, Flux Cored  and  also the Hot Wire TIG process.

Note: For those that may not agree with the above TIP TIG statement, why waste a breath arguing the subject, after all it would take less than 60 minute  for  a TIP TIG demo in any weld shop to prove the TIP TIG weld quality and cost results are superior to what your company is presently producing. Of course the local sales rep. that has a degree in liberal arts or history,  and  likely does not sell TIP TIG may disagree,  and instead perhaps they will want you to try their latest electronic MIG power source or another  useless three part MIG gas mix.

This site places much focus on the process expertise that’s too often lacking in global weld shops and also on the GTAW – Pulsed MIG – FCA and TIP TIG weld process comparisons for common, code quality global weld shop applications. Note, the weld  process comparisons will have more meaning when those that are interested in the comparisons, have the weld process controls & best weld practice expertise that’s been necessary to optimize the common arc weld process utilized in their weld shops. 

SO WHAT DO YOU THINK MAKES THE PERFECT ARC WELD PROCESS? If  I was to ask a well seasoned weld individual,  what do you believe the key  weld process attributes would be to make the perfect weld process for most code quality welds.  The following would be my list. 

Ten fundamental weld process requirements to attain the best possible, all position, code quality manual welds on any metals.

1.  Must be an easy to use, semi-automatic and automatic weld process.
2. Must have the weld capability for both open root and fill passes on any application and metals, and suitable to welds on any thickness.
3. Must provide the highest weld energy, (weld fluidity) capability to attain optimum weld fusion with all metals. (not possible with MIG or FCAW.
4. Must provide moderate all position weld deposition rates that while producing, cost effective welds are also providing an important balance between the amount of weld deposited and the weld energy delivered.
5. Must provide an inert plasma atmosphere that minimizes weld oxidation and porosity.
6. Must provide no spatter or slag.
7. Must provide automatic control of weld start / stop data.
8. Must provide EN polarity that enables with the weld speeds attained, the lowest welded part heat input that enables the smallest weld HAZ,  and the best  mechanical and corrosion properties.
9. Must be simple to set.
10. Must not require more than three settings for all welds.

Note in 2020 there is  only one weld process capable of delivering the above and it’s the decade old TIP TIG process. https://tiptigwelding.com

PLEASE BE AWARE, THAT EVERY  THING THAT’S  STATED AT THIS SITE,  I CAN  DEMONSTRATE  AND PROVE IN LESS THAN AN HOUR AT ANY WELD SHOP.

MODERATE WELD DEPOSITION RATES AND THE HIGHEST DC WELD ENERGY ENABLE THE BEST ALL POSITION WELD FUSION.  When the weld shop  has an all position,  easy to use  process such as TIP TIG that produces  moderate weld deposition rates that provide the highest energy and fluidity welds that are protected by an inert gas, for the weld shop this this enables the capability to attain on any scale application the highest possible arc weld quality. When you combine the weld quality asset of TIP TIG with the TIP TIG’s DCEN and weld speed ability to produce the lowest possible weld heat input to the parts welded, this provides for the weld shop, the manual and automated weld capability to eliminate the normally anticipated weld rework on any application. And also to be able to weld any type of weldable metal without worrying about any weld metallurgical concerns.  The TIP TIG welds shown on this page and in the TIP section cannot be duplicated by any regular  optimum TIG, pulsed MIG or flux cored welds.

Note. Yes with traditional DC TIG process the weler can always produce excellent weld quality, but with manual DC TIG,  the welder cannot attain the  TIP TIG weld energy,  the TIP TIG weld uniformity and weld continuity that drives weld speeds, the TIP TIG weld deposition rates and reduced skills  that drive weld costs, and with TIP TIG the weld shop can produce on most parts > 2 mm the lowest welded  part heat that influences metallurgy and application capability.

When I first introduced TIP TIG to N. America and Australia around 2009, I  was well aware that this  unique process would be a huge game changer for weld shops, and would have to be compared with the traditional arc weld processes utilized by the weld shops, especially with code quality welds. When discussing weld process comparisons,  it helps if those doing the process comparisons first have the weld  process controls and best weld practice expertise that was necessary to  consistently attain weld process quality and productivity optimization with the weld shop processes  they daily use. (available with my low cost weld process optimization training programs),  however the bottom line is simply this,  there is no optimum Pulsed MIG – GTAW and Gas Shielded Flux Cored welds that will have the capability to match the weld  quality show on upper left, and with the other TIP TIG welds shown here and in my TIP TIG section.

Some processes as discussed in the process section of this site are simply not capable of consistently producing optimum weld quality. Weld shops will be aware  that with manual welds, that irrespective of the welder skills, arc weld  processes such as Pulsed MIG and gas shielded flux cored are  on many applications simply not capable of  consistently delivering  defect free welds. The inherent weld process issues that influence the weld quality are discussed  extensively in my TIP TIG and in MIG and flux cored weld program sections.

Some of you that attended my process control workshops or purchased my weldreality training programs, will be aware that  I have specialized  on  the requirements for weld process control and best weld practice  for close to the five decades that I have been in this industry. Manual,  automated or robot welds, I know what each arc weld process quality – productivity and capability is with any metals on any applications. I am well aware also of the weld issues that will be generated from the weld process and consumables used, and also the issues that are generated from  the common poor weld practices used by the welders. So please keep this in mind in the weld advice that I offer,  I  was born in Manchester UK, and in general Mancunians are people that have good sense of humor with no time for BS. I don’t sell welding products, and from my lips  you will never hear weld equipment or  process bias. However for decades I do offer what in general is missing in the majority of weld shops of the global weld industry, that is the required Weld Process Controls and Best Weld Practice  self teaching / training  programs that will help any company  personnel attain the best possible weld results with the MIG – FCAW – Advanced TIG and also TIP TIG process utilized.  

If a person wanted to find evidence of the too often poor, stagnant state of the global weld industry, they  could start out in two diverse industries such as ship building and automotive. In most of the  global ship build facilities, thanks to lack of weld management and weld engineering ownership and lack of weld process controls expertise,  there is  usually always  extensive, unnecessary manual costly weld rework. And in the auto. truck plants, the bins that line the robot aisles will usually be full of weld rejects and rework from the poor robot MIG weld quality,  and few of the robots in the plants will be attaining optimum their robot weld productivity potential.

For decades.  as a result of  unnecessary flux core and MIG weld rework, millions of dollars have been  lost per-vessel built, and the reason is a simple one, the common Navy and shipyard front office,  lack of  Weld Process Controls and  Best Weld Practice Expertise.

Its 2020, and as they have done for decades, global Navy shipyards that are building multi-million dollar vessels will be dramatically going past their weld rework budgets often by millions of dollars,  and yet at these shipyard facilities the;

1. THE  REQUIRED WELD SPECIFICATIONS ARE BEING UTILIZED.
2. THE WELD PROCESSES WERE APPROVED.  
3. THE WELD PROCEDURES QUALIFIED.
4. THE WELDERS  TRAINED.
5. THE WELDERS WERE QUALIFIED.
6. AND THE QA DEPARTMENT DAILY STRIVES TO  ENSURE  THAT STRINGENT WELD INSPECTION WAS AN EFFECTIVE PART OF THE SHIP BUILDING PROCESS. 
7.  SO CAN YOU GUESS  WHY THE NEVER ENDING WELD ISSUES, AND WHAT THE MISSING LINK IS?

___________

With any facility that applies an annual budget for it’s anticipated  weld repairs, you would assume that the manufacturing management created that budget from its history of typical past, annual weld repair costs, You would also think that the key weld decision makers would then strive to reduce those weld repair costs. And yet in shipyards, you will find the annual weld repair costs rarely go down, and  in most cases again thanks to lack of management and engineering process ownership expertise, the weld repair costs typically will again, like the movie Groundhog Day,  repeat, and often dramatically exceed the weld repair budget sometimes by many millions of dollars.

WHY WITH SIMPLE WELD CONTROL ARC WELD  PROCESSES ARE THERE SO MANY WELD ISSUES:  A logical manager or engineer would ask, why with the  simple to set, two control, MIG and flux cored weld process that are utilized daily for the majority most arc welds, two processes that have hardly changed in many decades,  do the responsible managers and engineers  continue to fail in their task of  owning these weld processes and better managing their  daily weld quality and productivity?  Also why after decades of experience  with these two weld processes is there little evidence of weld process control and best weld practice evolution throughout the global weld industry?

Lets face it, anyone who had spent 30 minutes at this web site would not need to be a rocket scientist to figure out why the never ending shipyard or automotive plant weld issues have been going on for decades, or why most of the aerospace, power, oil and defense industries are stuck in the welding  20th Century. The following are five common root causes of  why many of the global weld issues occur;

[1] MANY MANAGERS ARE NOT AWARE THAT MANUAL – ROBOT WELD PROCESS CONTROLS & BEST WELD PRACTICE IS AN  EXPERTISE THAT EXISTS.

[2] FEW FRONT OFFICE  WELD DECISION MAKERS HAVE THE EXPERTISE TO  RAPIDLY WORK OUT THE COST OF A COMMON 1/4 6 mm MIG OR FILLET WELD. 

[3] ENGINEERS  AND TECHNICIANS ARE NOT TAUGHT WELD PROCESS CONTROLS AND BEST WELD PRACTICES. 

[4] MANAGER AND SUPERVISORS TAKE FOR GRANTED THAT THEIR  WELD PERSONNEL HAVE TO PLAY WITH WELD CONTROLS.

[5] MANAGERS & ENGINEERS & SUPERVISORS ARE NOT AWARE OF THEIR RESPONSIBILITY TO LEARN THE REQUIREMENTS FOR WELD PROCESS OWNERSHIP. 

I do apologize for the size of this web site, however its 25% of what it once was, however the weld processes and applications discussed are diverse, the weld process issues extensive, and the repercussions of costly arc weld quality and productivity issues that daily effect the majority of the global weld industry has been going on for the five decades that I have been in this industry.  However the weld reality is, the process controls  – best weld practice subjects should be of interest to anyone that calls them self a weld professional. 

Since the 1980’s I have been documenting the  common global arc weld problems that I was asked  to resolve  in more than a 1000 weld shops in 13 countries. I have written 35 articles and had four books published on  MIG and Flux Cored weld issues and process control resolutions. My focus was always on simplifying and condensing the subject of weld process controls and best weld practices and passing this on to all weld decision makers.  I have spent decades  developing the low cost process control resources available at this site that enable managers and engineers to take ownership of their weld processes, however the sad weld reality is getting them to purchase these resources, has in most instances  been like getting a mule to drink water from a trough. 

2109:  On the subject of lack of weld evolution, their will always be a place for the traditional TIG process, (left), however  as you will read below, this 75 year old process should no longer the optimum  arc weld process of choice with  most code quality welds.

In  this home page, I will start out with some  general information on the three key common arc weld processes that will be used in the next decades, Pulsed MIG, Gas Shielded Flux Cored and  the most important will be the TIP TIG process. The reader will find with these  three weld processes, the most comprehensive manual and robot weld  process control data in this sites programs sections and  also in my weld books and training materials. And while the site is long winded due to its age and  the never ending global weld shop issues, I hope some  readers will find the information that could enable any organization to take the one path required for weld  process optimization, a path that ensures with each of the three weld processes, the best possible, consistent, uniform quality welds always of course produced at the lowest weld costs.

As  MIG is the world’s most widely utilized arc weld process, you can never have enough MIG information.

FOR ME,  50 YEARS HAVE PASSED IN THIS INDUSTRY AND I SEE LITTLE CHANGE.  Some may think it ironic that most of the MIG weld issues that  I was writing about in the 1970 -80’s, are the same issues as the MIG weld  issues that are being  generated in 2020. Please note that extensive data  on the Pulsed MIG process and the extensive pulsed MIG equipment issues are  found in  the MIG programs  section.

A WELD REALITY IS THAT FEW WELD SHOPS WERE AWARE OF THE DECADES OF POOR PULSED MIG EQUIPMENT WELD  EQUIPMENT  PERFORMANCE,  WHICH IS SIMPLY ANOTHER INDICATION OF THE LACK OF WELD PROCESS EXPERTISE THAT PREVAILS THROUGHOUT THE INDUSTRY. 

If the reader was to  ask their experienced weld shop floor personnel to explain why they need pulsed MIG equipment for steel welds, I can assure you that in their answers there will likely be many indications of their MIG weld process confusion. And if the front office weld decision makers were asked why they should purchase pulsed MIG for  their steel welds, they will likely tell you all the reasons that their local sales rep. (who never ran a weld shop) told them.

I have written approx. a hundred  thousand words on why Pulsed MIG is not a requirement in a weld shop that welds mostly steel and alloy steel welds, and with the introduction of TIP TIG, when rational weld process selection decisions are made, the purchase of Pulsed MIG equipment should decline especially when any code quality steel welds are required. If like me you don’t have a life,  there are decades of manual and robot pulsed MIG issues documented in  my pulsed MIG process and MIG equipment sections.

[] WELDING ROBOTS QUICKLY REVEAL THE LACK OF  MANAGEMENT WELD PROCESS OWNERSHIP:

Pulsed MIG or regular CV MIG welds, you would think it logical that those responsible for robot MIG weld decisions would be aware of the weld process and weld transfer mode  differences, so they can best utilize the weld modes in the attainment of  robot weld optimization.  You would also think that the front office weld decision makers would be aware that their employees will in most instances lack the  robot MIG weld process controls and best weld practice expertise that’s necessary to enable consistent, optimum robot MIG weld quality and productivity, always  of course with the  lowest robot down time.

[] DECADES OF MIG WELD GAS SALES AND WELD SHOP BS: 

In North America, there are forty plus MIG gas mixes available, and few weld shops that are aware that  no more than four MIG gas mixes have ever been required for all MIG welds. The majority of the MIG Gas Mix mixes sold are simply a result from the vivid imagination of a of gas marketing  or sales executive. Note: As the industrial gas marketing manager for Airgas, AGA, and Liquid Carbonic, I developed or introduced in N. America 4 of the top selling MIG gas mixes. If interested visit my MIG gas section. 

[]  A WELD PROFESSIONAL  WITH OWNERSHIP CAPABILITY WOULD SIMPLIFY, CONDENSE AND ENSURE  EMPLOYEES ARE TRAINED  IN THE PROCESS CONTROLS – BEST PRACTICES REQUIRED.

No matter what weld wire is placed on a MIG power source and what the weld metal and application is, as shown in my Training / Self teaching MIG and Gas Shielded Flux Cored weld process control – best weld practice programs, the reader will find that  there are “three” optimum weld settings. There are also MIG and  Flux Cored best weld practices that are necessary to minimize  weld defects and optimize weld productivity. The weld reality is few of your  weld personnel will be aware of the settings and practices, and as is common in many weld shops when setting a MIG or Flux Cored weld, the weld personnel will  frequently   “play around” with two weld controls that have changed little in decades.

Around 2007, in a rare weld event for me, I had the opportunity to apply my arc weld process controls – best weld practices in a US shipyard in which the managers and engineers were much more familiar with SMAW (STICK)  weld practices that were likely established in the second world war.

When hired as the shipyard weld manager, I walked into a yard in which the previous weld and engineering manager knew a lot about stick welding and nothing about  Flux Cored and MIG Weld Process Controls and Best Weld Practices. In this shipyard. within three months of my process control training, the weld quality and productivity results were staggering. The weld quality and cost information attained is below, and full info available in my flux cored section. 

WITH THE EXCESSIVE  N. AMERICAN WELD REPAIR COST OVERRUNS  ON THE PRODUCTION OF NAVY VESSELS, AND WATCHING HOW QUICKLY  CHINA CAN BUILD SIMILAR VESSELS, AFTER DECADES OF DOING NOTHING,  US  NAVY SENIOR MANAGEMENT IS BEGINNING TO WONDER WHY THE LACK OF OF WELD MANAGEMENT / ENGINEERING PROCESS OWNERSHIP EXPERTISE HAS BECOME THE NORM. A LACK OF EXPERTISE  THAT DAILY  IMPACTS THE WELD QUALITY, PRODUCTIVITY AND PRODUCTION DEADLINES. 

As you will read below, even the Navy executives who will have never run a weld shop are beginning to wonder why in the  shipyards that build their vessels, the over budget weld repairs are  always measured in the millions,  and over the decades there has been little evidence of  management coming to grips with the costly weld issues, and  rarely evidence of the understanding or importance of the use of  weld process controls or best weld practices. 

THE ASSISTANT SECRETARY OF THE NAVY SPEAKS ABOUT THE COSTLY WELD ISSUES BUT MOST OF HIS DEFENSE CONTRACTORS DON’T KNOW HOW TO RESPOND

 For those not interested in my opinions and my focus on the general  lack of weld weld best practices and weld process controls expertise, they may however want to be aware of the the words of  a Mr. Guerts, the Assistant Secretary of the US Navy.  Mr. Guerts is responsible for spending approx.  205 billion dollars next year, and as you will read below, the front office engineering and management lack of  weld process ownership in the  Navy shipyard departments that fabricate & weld have him more than worried about meeting the his annual ship build delivery and budget requirements.  See Navy below.

2020…WHEN IT COMES TO WELDING NAVY VESSELS  SOME OF THE  GLOBAL NAVY SHIP YARD WELD DEPARTMENTS  APPEAR TO BE  STUCK IN THE 20th CENTURY. Another  2019 example of lack of front office management and engineering weld process  ownership.  There has never been a greater global demand for  submarines, however most of the welds produced when  building global Submarines,  will be made using outdated processes and outdated weld specifications and weld procedures.  It would take me an  hour to convince any Naval yard that there are simple weld process training and process solutions to many of their costly weld issues. 

For those front office weld decision makers that ignore or are not aware of the arc weld process  evolution that has taken place over the last ten years,  and  for those also not aware of the benefits of weld process controls and best weld practices that should be implemented in their ship building yards, you may when you  finish this page,  want to visit my process training – self teaching programs.  Watch out for the world’s most comprehensive process data on my tiptigwelding.com  website. 

2019.  The majority of the 21st Century global defense projects are at this time being built using 20th Century arc weld processes, with outdated weld specifications and  weld procedures. I am not aware at this time in 2019 of any North American defense contractor that has implemented the latest weld technology and uses weld process controls and best weld practices.

Process OWNERSHIP comes from My MIG – Flux Cored  and TIP TIG Manual and Robot Weld Process Controls & Best Weld Practice, Training or Self Teaching Materials.

WHILE MANY WELD SHOPS FOCUS ON “WELDER SKILLS”, IT’S BENEFICIAL IF WELD DECISION MAKERS UNDERSTAND THAT “WELDERS SKILLS” ARE NOT WELD BEST PRACTICES AND THE WELDER SKILLS ARE AN INDICATION OF THE WELDERS WELD  PROCESS CONTROL EXPERTISE:

A SINGLE WELD FAILURE CAN COST LIVES AND BILLIONS OF DOLLARS.  All it takes is one flux Cored, lack of weld fusion defect in the right application location. and with the right circumstances, the result can be a catastrophic human and cost disaster. However the irony is that in most global ship and oil platform yards, is that they typically provide inadequate welder training programs that focus on welder skills with minimal  focus on the requirements for weld process optimization. I suppose that this is understandable as few of the shipyard managers and engineers are aware of the importance of the weld process controls and best weld practices required with the common semi-automated weld processes.

WELD QUALITY – WELD LIABILITY.

This platform m was used to provide offshore  accommodations. All it took was a  poor 1/4 (6mm) fillet weld to influence  a structural component fatigue  failure and the platform collapsed into the ocean with  123 lives lost and billions in costs.

  frLstainless