"A
Management & Engineers Guide to MIG Welding Quality Costs Training"
656 pages
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Manufacturers,
Fabricators, Weld Quality, Productivity, Costs: When setting MIG and flux cored
welding parameters welders often "play around" with the wire feed and
volt controls, evident, by the pen or scratch marks that surround the controls.
Few weld decision makers know the optimum wire feed settings for the wire diameter
and mode of weld transfer used, even fewer welders know the wire feed position
in which the short circuit mode ends and spray transfer commences.
Control of the weld process is necessary if control of weld quality,
productivity or costs is your goal. This unique book presents and expands the
MIG and flux cored "Weld Parameter Clock Method". The clock simplifies
parameter selection for any weld. Tell a welder to MIG welds a 16 gage part with
short circuit transfer, at a wire feed setting of 210 in./min, 140 amps &
17 cups of coffee (17 volts), and watch the welder smile. Most welding decision
makers know the costs of welding consumables, few welding decision makers know
the costs of their welds. The clock method simplifies the control of MIG and flux
cored welding quality productivity. The clock method simplifies controlling welding
costs.
Weld Equipment, Pulsed MIG and Invertors: Costly electronic weld
equipment will not compensate for lack of weld process expertise. Over 100 pages
are provided on why pulsed MIG should not be used or used with caution for common
welded applications. Examine why pulsed MIG may reduce your weld fusion &
productivity potential. Compare and evaluate the pulsed MIG mode with regular
MIG short circuit, globular, spray transfer, metal cored and flux cored. There
are numerous reasons why sophisticated microprocessor power sources are not necessary
to achieve optimum weld quality or productivity. Weld equipment manufacturers
have their justification for selling microprocessors in welding equipment, in
contrast I have nothing to sell, only common sense weld advice based on >35
years MIG expertise.
Robotics:
Over 140 pages of welding solutions to robotic MIG welding applications are
provided. Reduce robot down time, improve arc starts, eliminate weld spatter,
reduces wire burn back and unnecessary contact tip replacement. This is the first
North American book that provides advice on how to achieve faster than traditional
weld travel rates. A unique seven step "Weld Process Control Program"
designed specifically for robot MIG welding cells will assist the weld decision
maker in attaining consistent quality & productivity.
Automotive
Welding: The North American automotive industry spends over 200
million dollars each year on MIG weld rejects and rework. This industry can anticipate
an extensive increase in its MIG welding problems as it expands its use of extruded
thin aluminum, and strives to MIG weld, thinner, coated, high strength carbon
steels. This book addresses the production and quality problems, and provides
the weld solutions.
Pipe
and Pressure Vessels: Optimum MIG or flux cored welding procedures
are rarely used in pipe shops. Emphasis is typically placed on the "welder's
skill." SMAW (stick) pipe welding requires extensive skill and "minimum
weld process expertise". MIG welding on pipe requires "extensive weld
process expertise". Who provides the stick welder the MIG or flux cored weld
process expertise they need when they change from stick to MIG or flux cored?
Pipe shops often misinterpret lack of "MIG weld fusion defects" in radiographs.
The lack of process expertise and the extensive lack of pipe weld fusion that
goes into pipe welds can have serious liability consequences for pipe shop owners.
This nook provides unique, MIT pipe welding procedures developed by the author
to minimize lack of pipe weld fusion.
Welding
and Sales Advice: Sales advice often negatively influences the selection
of welding equipment and consumables. Many weld gas mixes are selected based the
advice of a salesman. The gas mixes are rarely selected based on arc physics,
weld oxidation, or weld energy potential. The most popular gas mixes sold the
North America are argon-CO2-oxy tri-mixes. The tri-mixes are a poor choice for
many common applications. Cut through the gas product hype that surrounds the
30 plus available gas mixes, and read unique gas mix solutions for manual and
mechanized carbon steels, stainless and nickel applications. Weld decision makers
should be able to differentiate practical weld advice from, product bias, or sales
hype.
The
Educational Challenge. Many universities, colleges and trade schools
fail when teaching the MIG and FCAW process expertise that the welding industry
needs. This book would be a valuable asset for these institutions.
