Welding Process Controls and Best Welding Practices Programs.

The most unique, comprehensive MIG, Flux Cored, TIG & TIP TIG, self teaching & training, weld process controls and best weld practice programs.

 Heard in too many weld shops. “Why change, this is the way we have always done it.” or “can you give me some time to play around with the weld controls?

During the 1990’s in my position as the Corporate Weld Mgr. for ABB. Robot Div, North America, I provided my unique robot weld training programs which I had been developing during the previous decades.  As it was at that time and still is today, this robot process  program is the most comprehensive self teaching / training program ever developed on the subject of  Robot MIG Weld Best Practices and Weld Process Controls.

Unfortunately in the 1990’s, the senior management, engineers and supervisors at most global auto – truck companies were not aware of the expertise required to implement robot weld process controls that their employees require to attain robot weld quality – productivity optimization. Thirty years later and here we are in 2018 and  on this subject little has changed in most front offices. However the programs I developed have continued to evolve yearly, and they will be the the tool any global company needs for it’s employees require for robot MIG weld optimizations.,

Process confusion requires process resolutions, and those resolutions won’t come from a salesman.

Home Page 1. From Ford to Chrysler, or Tesla to GM, few of the global MIG weld robots utilized daily will attain their weld quality or weld productivity potential.

  • Its time that  the Auto industry robot weld tech stopped making unqualified weld changes to robot welds.
  • A look at the root cause for global manual and robot MIG,  flux cored  and TIP TIG weld process confusion.
  • Manual or robot WELD COSTS,  who in the front office has a clue?
  • The global negative influence of SALES ADVICE on manual – robot weld quality, productivity & costs.
  • Why lasers and aluminum have a hard time in the global auto industry.
  • From Navy yards to auto plants, billions of dollars lost each years due to poor weld  management.
  • Its easy to solve the global  skilled MIG – Flux Cored welder shortage.
  • Chrysler management looses  hundreds of  millions of dollars annually on  simple robot welded parts.
  • Ford, reasons for it’s robot steel frames and aluminum MIG weld issues.
  • Why it’s difficult to  trust a Chinese company to produce optimum weld quality.
  • Few global MIG welding robots achieve their production – quality potential.

 Home Page2. When it comes to welding, why many managers and engineers raise the white flag 

  • Dow Chemical engineers stuck in a 1960’s weld time warp.
  • Magna techs, lots of attitude, lacking in  Robot Process Control expertise.
  • What do ship yards and auto plants have in common?
  • Why the common global QA weld inspection practices often fail.
  • When the Chrysler welds fail, they ship the parts to Mexico.
  • Nothing more ridiculous than FEMA involved with USA weld specs.
  • Would Einstein have this a similar theory on MIG welding?
  • Self Shielded flux cored wires effect on North Ridge Earth Quake welds.
  • Motoman and Panasonic numerous robot / weld weld issues.
  • Welding, why the managers and supervisors raise the white flag.

Home Page 3. Why most global  front office mfg. personnel lack the ability of process ownership.

  • Volvo manager was wrong in wanting to hire skilled welders to run robots.
  • Lawyers may want to read how the common, poor robot welds affect vehicle integrity in crashes.
  • No manager or engineer weld process ownership at  this Volvo truck plant.
  • The fear of front office weld process changes is what creates the “why change” weld shop mentality.
  • More engineers than they need in the auto plants, yet best weld practices & process controls are typically none existent.
  • Why most manufacturing managers do not report their real robot weld quality and productivity costs  corporate.
  • Most designers of welded parts have no expertise or interest with the process used to weld their parts.
  • Why Americans should give more consideration to  welds,  before they drive across the next steel bridge.
  • This large auto – truck wheel mfg. produced poor quality welds that helped drive this company out of business.
  • The importance of front office personnel weld process ownership?
  • GM  management weld process ignorance with  the Corvette.

It’s a sad reflection on the global weld industry, that for decades,the majority of companies that utilize MIG robots will not be aware that the robots they own will have rarely reached their weld quality or weld production potential.

Home Page 4. For decades,  Japan made the worst MIG welding equipment.

  • Their were many weld issues in the plant, and as usual the weld management were blaming the wrong people.
  • How this costly Lincoln pulsed MIG power source compares with the least costly CV Lincoln MIG power source.
  • it was the Miller Maxtron &  Miller Invision that helped put this global Wheel Mfg. into Chapter 11.
  •  How MIG equipment manufacturers cheated weld shops by not informing about their equip. issues.
  • For decades Japan made the worst MIG equipment.
  • Most Japanese automotive and  truck weld specifications belonged in Disney Land.
  • Why that costly pulsed MIG power source for gauge metals is usually not required.
Optimize both Manual and Robot MIG Welds.


MIG Welder solutions to manual and robot weld issues on THIN steels using Short Circuit,


MIG welder solutions to manual and robot weld issues on THICK steels with Spray transfer
.


Pulsed MIG 
welding  issues  & resolutions.

Pulsed MIG for Clad welds.

Pulsed MIG weld Equipment Evaluations without sales  influence.


Manual & Robot MIG Weld COSTS Made Simple.

Lack of effective Robot MIG Weld Management.  

MIG welding Aluminum, weld issues and resolutions,

MIG Weld GAS information without Sales BS

MIG Arc Blow resolutions for the welder.


Weld Fumes &  Weld Safety.


The majority of the global robot and manual MIG welds, and also robot resistance welds are rarely optimized in most auto – truck plants. In the 1990 ‘s I started an auto -truck industry BAD WELD Section. Note, after a decade I had to stop with the inputs in this section as the auto – truck bad part weld  recalls reported on the web were simply endless. In 2018 little  has changed now  and when it comes to weld issues I am sure Tesla will know that story.  One thing that should frustrate any engineer. manager, supervisor or technician that deals with arc welding robots, is why over five  decades does the global weld industry seem to lack the ability to control the MIG  process, with only two simple weld controls?

All the robot  and manual MIG weld process control personnel will ever need is in my MIG process control program.


Welders or Managers, test your Weld Process Control Knowledge with my MIG Quiz.

Bad welds, bad welds, what’s the management gonna do?

The consequences of management and engineers who fail to understand the importance of weld process control expertise and the implementation of the best weld practices that are necessary to optimize weld quality, minimize weld costs and reduce weld liability consequences.

Bad welds in global industries.

Bad welds, auto – trucks with focus on Ford.


Bad welds & recalls. Chrysler – GM – Buick – VW – Honda – Nissan – Mitsubishi – Mini – Land Rover- Hyundai, its the whole bloody industry that has a problem with a two control process.

Optimum Gas Shielded Flux Cored Welds, without playing around with the welding controls:

This welder was qualified at the largest US ship yard to the ABS Weld Certification requirements.

Flux Cored & MIG PIPE weld problems and resolutions.

Flux Cored & poor weld management in Ship Yards & other large weld shops.

Examine how to easily fix  weld & fabrication quality – costs issues that are common to most ship yards..

Self Shielded Flux Cored Wires and the many weld Issues they generate.

Self Shielded Flux Cored Wires influence on the North Ridge Earthquake.


Test your Gas Shielded Fllux Cored weld process knowledge with Ed’s Weld Quiz.

Flux Cored Weld Issues / Resolutions in SHIP YARDS.

Welders often shy away from weld automation as they are rarely taught the required weld process control requirements.

Establishing manual or automated welds, the weld shop personnel should be able to provide answers to simple weld questions like this?

MIG: Lets see, this is a common, automated carriage weld making a 1/4 (6 mm), MIG SPRAY fillet weld. The MIG wire is 0.045 (1.2mm) and the gas mix is the common argon 80% – 20% CO2.

  • I set the MIG WF at ____.
  • The MIG weld volts will be____.
  • The carriage weld travel rate is ____.
  • The best torch angle is____ degrees.
  • The best torch push angle is ____ degrees.
  • Woops getting spatter, I better _____the volts.
  • Woops, getting undercut, I better____ the_____.
  • The weld is oversize, so I can increase the weld speed without touching the WF, so now I have to _____the weld volts.

FLUX CORED:  The next weld I have to set on that automated weld carriage is with a 1/16 (1.6 mm) E70T-1 flux cored wire with a CO2 gas welding the same 1/4 fillet weld. Could you then provide the flux cored wire data

  • Set the flux cored wire feed ____ inch/min.
  • The FCA weld volts will be____.
  • The carriage weld travel rate is ____.
  • The best torch angle is____ degrees.
  • The best torch push angle is ____ degrees.
  • Woops getting spatter, I better _____the volts.
  • Woops, getting undercut, I better____ the_____.
  • The weld is a little oversize so I can increase this weld speed without touching the wire feed, so now I have to _____the weld volts.

This or any weld data would be no big deal, if you learnt my Weld Clock process control method which makes it easy for me to remember weld data for any MIG – Flux Cored consumables or weld. Remember, if you have to ask about MIG or Flux Cored weld data, or you play around with weld controls, can you call yourself a “weld professional”.

Ed’s MIG & Flux Cored, Self Teaching – Training, Weld Process Control – Best Practice Resources.

Advanced TIG and TIP TIG..

TIG welds on Aluminum & other metals.

Using advanced TIG equipment can cause confusion in many weld shops in which the weld personnel  may not fully comprehend the new electronic features available with advanced TIG equipment that offers more process controls than the TIG welders may be used to.

With advanced TIG power sources you will have options such as Balance Wave and Hz controls that  can offer amazing improvements  with all  TIG welds. However in an industry that’s slow to embrace change, if these new electronic process control features are not used or under utilized, then why purchase the premium priced TIG equipment in the first place? Remember there are consequences when the highest weld quality at the lowest weld costs is consistently not attained

My TIG self teaching – training program available in the training resource section simplifies and provides the best possible training  methods  and weld practices that anyone would require to attain the best possible results with advanced  TIG equip.

TiP TiG Welding information. 

TIP TIG is simply the best arc weld process for any metals and and for all code quality welds.  If you or your company is using regular TIG for your manual TIG welds, or Hot – Cold Wire TIG,  for your automated TIG welds, you are likely wasting extensive labor costs and resources, and also reducing your weld & part quality potential.

2018: For those interested in attaining the highest weld quality at the lowest costs, for the majority of alloy weld  and code quality weld applications, the regular TIG process should more than a decade ago have been replaced by the TiP TiG process.

Ed provides an advanced TIG and TIP TIG self teaching / training program. These two programs simplify the two processes and provide  the most comprehensive data ever written, and also reveal the unique weld and application differences between TIP TIG, regular TIG and the Hot /Cold Wire TIG processes.

Ed introduced TIP TIG  to both North America and Australia around  2009.

Oxy Fuel Cutting Gases & Cutting Data:

Info on Acetylene, Propane, Nat Gas, Propylene & Mapp Gases.

If you don’t apply process controls and best practices to your oxy – fuel cutting applications, you have missed an opportunity to maximize the profits you could have attained

Oxy Fuels. Information and Cutting Data.