Welding Process Controls and Best Welding Practices

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

Home Page 1.

  • 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.

Home Page 2.

  • 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.
  • Why the weld managers and supervisors raise the white flag.

Home Page 3.

  • 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 requirements for front office weld process ownership?
  • GM robot weld management, weld process ignorance & the Corvette.

Home Page 4.

  • 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 equipment issues.
  • For decades Japan made the worst MIG equipment.
  • Most Japanese automotive and truck weld specifications belonged in Disney Land.
  • Why a costly pulsed MIG power source for gauge steel metals is usually not required.

Optimize both Manual and Robot MIG Welds.

      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

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.

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

Welders often shy away from MIG or flux cored weld automation as few have ever learnt the required weld process control – best practice requirements.

  • – 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”.

Advanced TIG and TIP TIG..

TIG welds, 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 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 Craig introduced TIP TIG to North America and and then with business partner Tom O’Malley to Australia around 2009.

Oxy Fuel Cutting Gases & Cutting Data

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