2007: One of my prime welding goals during the last forty years has been "Weld Process Control Simplification". During the last three decades, FCAW has been painfully slow in it's evolution due to the general global process confusion and the fact that when the product was presented to weld shops, few weld personnel could set optimum FCAW weld parameters.

In this flux cored training program. I present a unique, simple solution to ensuring everyone understands where to set the optimum, all position flux cored weld parameters and MIG pipe root parameters using either standard or digital feeders and Inverters and traditional CV MIG equipment. You do not need weld process expertise to present this program. Simply point and click and you will find the program will take you on a path to the establishment of Best FCAW Weld Practices and Weld Process Controls.

THE VALUE OF PROCESS CONTROL KNOWLEDGE: When you can instantly address the root cause of your daily flux cored weld issues and you have the process knowledge to prevent those issues, you know the value that brings to you and your welding company.

 

This program provide the resolutions to;

[] lack of weld fusion,
[] weld and HAZ cracks,
[] excess weld slag entrapment,
[] excess weld porosity.
[] cut the time by 50 % when welding excess root gaps on ceramic backing.

If your organization uses the E70T-1 / E71T-1 wires, and welds fillet welds, open root pipe joints and pressure vessels, all position structural welds, plate vee groove weld joints, or welding vee grooves with "ceramic" or steel backing, this training program enables instant, optimum flux cored weld solutions to all your gas shielded flux cored weld quality and productivity issues.

 

[] Imagine a weld shop in which every welder and supervisor knows how to set optimum, all position flux cored weld data, (no playing around with the parameters) on any carbon steels and stainless, all position applications.

[] Imagine a weld shop in which the weld personnel have the ability to instantly set optimum MIG weld parameters for those short circuit, STT or RMD pipe root passes.

[] Imagine a shop in which welders and supervisors understand the unique differences between all position welding on a pipe vee groove with a 3 mm open root and and welding a plate vee groove with steel or ceramic backing and root openings from 8 to 25 mm.

[] Image a shop in which welders and supervisors are aware of the skills and technique differences between stick welding, GMAW and flux cored welding.

[] Imagine a shop in which managers, supervisors and welders understand the application locations most prone to weld defects and provide parameter and technique solutions to reduce the weld defect potential.

[] Imagine a weld shop in which a welder picks up a Bug-O (automatic carriage) and the welder actually knows the optimum weld parameter, weave and weld speeds for that 6 mm fillet weld.

The flux cored requirements for "optimum root, fill and cap weld passes" will rarely come from the weld supervisors mouth or from the weld procedures tucked away in the quality managers office.

[] Imagine a shop in which welders, supervisors and managers understand the unique all position flux cored weld parameter and technique requirements for vee groove welds with ceramic or steel backing.



THE IMPORTANCE OF GAS SHIELDED FLUX CORED WELD PROCESS EXPERTISE:


[] The fact that your weld personnel have to "play around" with the flux cored weld data should tell you something.

[] Ask ten welders to turn up the weld heat, five will increase the weld voltage and five will turn up the wire feed.

[] I hope you are aware of why flux cored weld weaves in vee grooves should be minimized.

[] The fact that many of your welders will only use one setting to weld everything is another indication of the lack of process expertise in your organization.

[] In many facilities such as ship yards and pipe shops, the weld process transition was from the stick welding to the flux cored process. Many of the welders in these facilities who are using the flux cored process will use "stick or MIG welding techniques" that are not suited to the flux cored process.

 

WHY DO YOU NEED THIS PROGRAM?

[] You know the cost of your NDT.

[] You know the cost of your weld rework.

[] You are not quite sure if the welders are producing maximum weld depositions rates for the application.

[] You know the cost of a poor weld reputation and weld product liability.

[] You would like your weld personnel to have an easy to remember method for setting optimum welding parameters for any flux cored application.

[] You want your weld work force to be professional in their approach to all position welding and you have to want them to provide a uniform approach to the weld processes they use.

[] You know that the weld procedures you have in the office cabinet are not dealing with the real world variables that daily influence the weld quality and productivity.

[] In your shop, your weld personnel will tell you 10 different ways to produce that vertical up weld. You know that their has to be a Best Way, a Uniform Approach to dealing with the unique requirements of all position root, fill and cap pass welds.

[] You know its time for your shop to establish Best Weld Practices. As you look around your weld shop, you know in the last decade your company has tried;

(a) ten different weld consumables,
(b) seven different weld power sources,
(b) ten different MIG gas mixes.

[] You know its difficult to find good welders, yet this program makes excellent welders with a few hours training.

You know in 2007 that it's time to establish a highly cost affective Weld Process Control Training Program

Note: This program also provides MIG requirements for optimum, all position open root pipe welds

WELD EQUIPMENT COSTS: A great additional benefit of this program is to eliminate the sales induced process hype that surrounds MIG weld equipment selection. This program shows you which power source has the best weld transfer characteristic's, is the most durable and cost effective for the MIG and flux cored weld consumable discussed. This program will dramatically reduce your weld equipment, consumables and equipment maintenance costs.

 

MANY MANAGERS / SUPERVISORS / ENGINEERS HAVE NEVER FELT
COMFORTABLE ABOUT UNDERSTANDING WELD COSTS?

WELD COSTS: This program provides Ed's unique simple approach to weld cost controls. The program enables engineers, supervisors and managers to simply glance at the wire feed control and be aware of the welders production performance and the cost of that weld.

WORRIED ABOUT FINDING WELDERS? WORRY LESS:

"WELDERS WANTED" When a simple method is used to educate the personnel on how to master a welding process, that program improves the process confidence level of those workers and dramatically reduces the time required to create a highly effective weld work force.

Ed has provided training to thousands of workers in ten countries. With this program you can take a worker with no previous weld experience and in forty hours training enable that worker to weld all position pipe / plate welds that will consistently meet the highest global weld code standards.

THIS PROGRAM BUILDS IT'S WELD PROCESS / TECHNIQUE RECOMMENDATIONS AROUND WELD DEFECT PREVENTION. YOU HAVE TRIED THE SALES ADVICE AND LOOK WHERE THAT TOOK YOU. WHY NOT GET REAL WORLD WELD BEST PRACTICE ADVICE FROM SOMEONE;

[] WHO HAS TESTED MIG EQUIPMENT AND CONSUMABLES FOR 40 YEARS,

[] WHO HAS ADVISED OVER 1000 COMPANIES IN 10 COUNTRIES ON HOW TO SOLVE THEIR MIG AND FLUX CORED WELD ISSUES AND HOW TO INCREASE THEIR WELD PRODUCTIVITY,

[] WHO HAS WRITTEN MORE THAN 2000 PAGES ON THE SUBJECT OF WELD BEST PRACTICES / PROCESS CONTROLS:

[] WHO HAS DEVELOPED THE WORLD'S MOST EFFECTIVE WELD PROCESS CONTROL BOOKS AND TRAINING RESOURCES.

SKILLED WELDERS: With this 5 to 8 hour classroom session and training skilled weld personnel, provide the welders with 4 to 8 additional hours of hands on, utilizing the recommended procedures, practices, skills and techniques provided, the results will be dramatic in the weld coupons they will produce.


PERSONNEL WITH NO WELD EXPERTISE: With personnel who have never welded, extend the hands on training for the balance of the week. The results will amaze you. In fort hours you will have a weld work force that truly understands how to daily minimize weld rework and attain maximum weld productivity.

With 40 years of hands on MIG and flux cored weld process control expertise, five books and 30 plus articles on the subject, Ed is one of the world's leading process control experts on the flux cored and MIG processes. He has provided process control training to over 1000 companies in ten different countries. Pipelines, ship building, power plant, nuclear, waste energy, refineries, light / heavy fabrication and too many auto/ truck plants.

 

The training CD
$275. To order.

 

Ed strives for weld process control simplification. You don't need a welding back ground to present this program, all you need to do is press "click" and let the program speak for itself.

Need more information call Ed at 828 658 3574.

[] Link to a training session Ed provided on flux cored Pipe welds. Imperial Oil Alberta

[] Link to Ship Building and the consequences of Bad Flux Cored Welds

[] Link to a flux cored hands on work shop provided by Ed at the Philadelphia Naval Ship Yard

For more info contact Ed at E-mail ecraig@weldreality.com.

Call Ed at Asheville North Carolina. 828 658 3574 or cell 770 330 9933.

Back to Ed's Train Resources to order and view other process control programs.