THIS YEAR IN NORTH AMERICA OVER 400 MILLION DOLLARS WILL BE USED FOR UNNECESSARY FLUX CORED WELD REWORK. AS LESS THAN 10% OF THE PIPE AND PLATE WELDS WILL BE SUBJECT TO NDT AND REQUIRE EXTENSIVE COSTLY WELD REWORK, IT MAKES YOU WONDER ABOUT THE LEVEL OF FLUX CORED WELD PROCESS EXPERTISE IN WELD SHOPS AND THE QUALITY OF THOSE 90% REMAINING WELDS.

Its important for mangers to realize that weld skills have little to do with weld process controls expertise. Any weld facility that provides weld process control training should anticipate an immediate dramatic decrease in weld rework and an extensive increase in weld productivity.

Too frequently the well established weld procedures in most weld shops do not provide weld personnel with the unique process data that can compensate for the many variables at their facilities that affect the weld quality and productivity. When welders have to deal with the variables they typically will leave the weld parameters alone or "play around" with them.

Ed's weld process control training / educational resources examines the common root causes of all weld issues and provides the weld process controls, techniques solutions that will dramatically lower weld rework potential and optimize weld productivity.


[] PIPE / PLATE ROOT CAUSE AND SOLUTIONS: Weld procedures typically don't deal effectively with inconsistent or poor weld edge preparations, and the common variables and root gap dimensions openings that are common to every pipe and plate shop. The flux cored CD power point program deals with the root causes for flux cored weld defects and failures and provides highly effective, process, techniques solutions.


[] PIPE / PLATE ROOT CAUSE AND SOLUTIONS: The all position root, hot pass, fill passes and cap pass in each vee groove weld layer can offer unique weld challenges. This program provides the optimum flux cored weld process parameters and technique that will minimize weld cracks, and reduce the potential for lack of weld fusion, slag inclusion and porosity. The program places focus on pipe / plate vee groove weld's hot pass and first fill pass locations as this is where most of the all position vee groove weld defects occur.

[] ROOT CAUSE AND SOLUTIONS: WELD PROCESS EXPERTISE:

[] In many facilities such as ship yards and pipe shops, the process transition was from the stick welding to the flux cored process. Many welders using the flux cored process will use "stick welding techniques" that are not suited to the higher weld energy, higher weld deposition rate flux cored process.

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

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

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

[] Few global companies that weld, use ceramics for root backing. Flux cored welds on ceramic backing require unique weld techniques and parameterss that are rarely found in the weld procedures sitting in a cabinet in the quality managers office. This training program provides the missing link common to all weld shops, "lack of flux cored / MIG process control expertise".

GLOBALLY, 100 PLUS MILLION DOLLARS WILL BE WASTED ON OVER PRICED MIG EQUIPMENT WITH UNNECESSARY ELECTRONIC BELLS AND WHISTLES AND MILLIONS MORE WILL BE SPENT ON REPAIRING WELD EQUIPMENT THAT CAN BARELY GET TO THE END OF IT'S WARRANTY PERIOD.

[] SAVINGS FROM WELD EQUIPMENT COSTS: Most pipe and pressure vessel shop will purchase weld equipment influenced by sales bias. The equipment typically may have useless bells and whistles, and the equipment rarely makes it through the warranty period without the need for repair.

Most ship yards will pay one to three hundred thousand dollars each year to replace / repair MIG weld equipment that should be lasting two to three hundred percent longer. Thi progran shows you how to dramatically reduce your weld quipment costs and reduce those weld equipment maintenance head aches.

FEW GLOBAL COMPANIES ORDER THE CORRECT WELD CONSUMABLES THAT ENABLE MAXIMUM WELD PRODUCTIVITY AND ASSIST IN REDUCING THE WELD REWORK COSTS.


[] In many companies it's common to see the wrong size MIG and flux cored electrode wire selected, the wrong type of flux cored consumable and the wrong weld gas.

Every flux cored wire manufacturer makes what they think is their unique E71T-1 all position weld wire. This program reveals the weld consumables and equipment that gets the job done with the highest possible weld quality at the lowest possible costs.

[] The weld cost focus in many weld shops is on the costs of the weld consumables rather than on the costs of the welds, the deposition rates or real world weld production potential. This program provides managers, engineers and supervisors a simple solution to attaining optimum weld productivity and a simple method to understand the requirements to controll weld costs.

WHEN YOU LEARN THE PROCESS CONTROLS PROVIDED IN THIS COURSE, YOU LEARN A SIMPLE METHOD TO UNDERSTAND AND CONTROL THE COSTS OF YOUR WELD.

[] YOUR WELDERS HAVE ON AVERAGE BEEN STICK WELDING SHIPS, CARS, TRAINS, TRACTORS OR PIPE LINES FOR 20 YEARS, WHY DO THEY OR THE SUPERVISORS, ENGINEERS OR MANGERS NEED FCAW PROCESS CONTROL TRAINING?

Flux cored is a high energy, high weld deposition weld process. In contrast, SMAW is a low energy, low weld deposition rate process. SMAW requires minimal process expertise. SMAW is all about the welder's skills and slow weld speeds enabling the welder time to manipulate the electrode either side of a vee groove and pinpoint the small fast freeze weld puddle.

In contrast to SMAW, the flux core process is about understanding the wire feed and voltage settings and their suitability to the application. This is a process in which wire stick out changes can change the weld mode of transfer or provide a dramatic change to the weld energy level. With the FCAW process the use of a weld voltage that is one volt too high or low can create weld instability for the welder. This process results in higher weld speeds requiring different weld techniques and different weld profiles. The bottom line, FCAW is a very different process than SMAW, its a weld process in which all weld personnel including managers, supervisors, welders and QA people can benefit from Process Control Training.

Ed's programs provide a truly unique simple training approach that after a few hours, weld personnel who have never before welded will master the process and optimize the parameters for any applications with out playing around with their weld controls.

This program will quickly turn a novice welder into a welder that can meet all position weld code requirements. For the skilled weld personnel the training results will be immediately measured in a dramatic cost reduction in weld rework and increased weld productivity.

WITH ED'S UNIQUE SIMPLE APPROACH TO PROCESS CONTROLS YOU WILL WORRY LESS ABOUT GETTING SKILLED WELDERS OR IMPROVING YOUR EXISTING WORK FORCE. AS A WELD DECISION MAKER YOU KNOW ITS LOGICAL THAT ALL WELDERS, QA PERSONNEL, TECHNICIANS, ENGINEERS, SUPERVISORS AND MANAGERS WALK THE SAME PATH TO WELD QUALITY OPTIMIZATION AND WELD COST REDUCTION.


USE THIS PROGRAM TO TEACH YOUR SELF OR TEACH A 100 WELDERS. THIS PROGRAM IS IDEAL FOR SHIP BUILDING, REFINERIES, OIL RIGS, BRIDGE BUILDING, STRUCTURAL AND HEAVY EQUIPMENT COMPANIES, PRESSURE VESSEL AND ALL PIPE SHOPS.

For information on Ed's MIG or Flux Cored weld process control programs
E-mail Ed at ecraig@weldreality.com, or call day or evening, Eastern Time USA.
Phone Ed at 828 658 3574. For Ed's MIG and Flux Cored Books and Training Resources, click

If you believe the weld personnel in your organization have control of the FCAW process, they should readily pass Ed's Flux Cored Weld Quiz:

Link to a flux cored pipe training program Ed provided for Imperial Oil Alberta

Link to Ship Construction and bad flux cored welds