The MIG Welding Management Book.

 

"A Management & Engineers Guide to
MIG Welding Quality Costs Training" (656 pages).

MIG Weld Process Controls: When setting flux cored and MIG welding parameters, welders often "play around" with the wire feed and volt controls, evident, by the pen or scratch marks that surround the controls. Playing around with controls has to impact weld quality, productivity and costs , yet 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 positions 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 weld clock simplifies MIG and flux cored parameter selection for any weld.Tell a welder to MIG weld a 16 gage part with a wire feed of 210 inch/min, 145 amps and 17 volts and watch the welder frown. Tell the same welder to use short circuit transfer and set the wire feed 10 o'clock with 17 cups of coffee, and watch the welder smile.


Simplify Weld Costs: Most welding decision makers know the costs of welding consumables, few welding decision makers know the costs of their daily weld deposition rates or the costs of the common welds they produce. The weld clock method simplifies the control of MIG and flux cored welds and this unique process control method simplifies weld costs.


Justify Low Cost MIG Equipment: Pulsed MIG equipment and Invertors and other costly electronic weld equipment, will not compensate for lack of weld process expertise. Over 100 pages in this book are provided on why pulsed MIG should not be used or used with caution for common steel 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 costly, 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 this book, common sense and weld advice based on 45 years MIG expertise.

E-Mail to Ed.

Love the site, its a great weld resource and a comforting reassurance that I really wasn't the problem. I have been welding for 17 years and had different gases thrown in my face by salesmen along with extensive weld advice and parameters that just didn't seem to make sense, not to mention all the "learning curves" that I seemed unable to attain. With your Management / Engineers book, I finally have found the process control book that I need.

Regards. Kevin Gough.USA.

Robotics: The North American automotive industry spends over a billion dollars each year on robot MIG weld rejects and rework. This industry can anticipate an extensive increase in its MIG welding problems as it expands it's use of extruded thin steel and aluminum parts and strives to MIG weld, thinner, coated, high strength carbon steels. This book addresses the robot weld production and quality problems, and provides the weld solutions.

Over 140 pages of welding solutions to robotic MIG welding applications are provided.

Reduce robot down time, fix arc instability, eliminate weld burn through, under cut, crater issues. Ensure consistent weld fusion, improve arc starts, eliminate weld spatter, reduce wire burn backs to the tips and unnecessary contact tip replacement. This is the first global book that provides advice on how to achieve faster than traditional robot weld travel rates and the unique "Seven Steps to Weld Process Control Program" which is designed specifically for robot MIG welding cells, will assist the weld decision maker in attaining consistent robot quality & productivity.

Note from Ed. If you work with robots the most comprehensive robot Best Practices and Process Controls training program ever developed is one click away.

Note from Ed. If you work with manual MIG or flux cored, the most comprehensive Best Practices and Process Controls training program ever developed is one click away.

MIG Welding Book Testimonials

E-Mail:

I spoke with you on the phone a couple of weeks ago. Well contrary to the beliefs of my co-workers I must say your concepts on GMAW are worth trying. Your story of reading weld literature and finding it was not as it seems inspired me to do the same. Over the last three years all I have done and continue to do is read from a variety of welding resources. So this past week I have focused my study on the "hands-on" practical aspect. Its amazing what you learn from having your nose in the arc rather than observing from out side a fence. From this approach I now fully understand how and why globular transfer is not a reliable mode of transfer, especially when utilizing it for high travel speeds (50- 70imp). Tonight thanks to your books I was able to figure out how you achieved robot speeds of 70 to 100ipm in spray mode. I went snooping around the plant and found an old style of gas diffuser that was shorter than our common ones. I then took your advice from your WELD MANAGEMENT AND ENGINEERS book and cut about a 6 mm off the end of a tip. With having the tip recessed in to nozzle allowed for a longer stick out dropping the amperage but still within the spray range. The longer wire stick out permitted me to run higher WFS (deposition rate) without the extra amperage that would cause unwanted weld defects like weld burn through. The spatter was minimal and easy to remove. Also the recessed tip and diffuser were spotless. A

Ed Thanks for your contribution to my weld education.
Matt Finn. USA.

E Mail to Ed.

I have just read your Chrysler Neon article regarding the cross members and self shielded flux cored wire issues. I fully endorse your views and comments. Its a shame that many "weld engineers" in the automotive industry lack the actual knowledge and skills to fulfill this critical role. I myself am a welding engineer for a tier one supplier to the UK auto industry and see this too often. As an engineer and also time served boilermaker, I feel that there is a tremendous lack of MIG weld process knowledge and experience with the welding and engineering personnel in the auto industry. I must also thank you for your SDs / books especially the " Management & Engineering Guide to MIG" We as a company refer to them regularly. Cheers

PL - England.

Pipe and Pressure Vessels, Ship yards Oild Platforms or Construction Projects: Weld procedures may be qualified, however once you get in that weld shop or out on the constrution site, in the world of numerous weld variables you will find that optimum MIG or flux cored welding practices and process controls are rare and the weld focus is always placed on the "welder's skill."

 

HOW NOT TO PRODUCE A PULSED MIG CLAD WELD.



2008: Compare what lack of weld process controls achieves
from the above photo (clad welds on boiler water wall tubes)
to what can be attained, below.

2005: Ed's Pulsed MIG clad welds. Inconel 625. Vert down. Single pass.

Inconel filler Metal required less than 25% than the norm used. Single pass clad weld dilution less than 6%. Single gun weld deposition 15 lb/hr. Ed changed the way that globla Boiler Water Walls will be clad using pulsed MIG with both Inconnel and stainless consumables.

The SMAW (stick) pipe weld process requires extensive skill, yet this process also requires minimum weld process expertise. In contrast MIG welding on pipe requires "extensive weld process expertise". Who provides the welder with the MIG or flux cored weld process expertise they need when they change from stick to MIG or flux cored welds?

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 book provides unique, MIG pipe weld data developed by the author with one goal in mind, minimize lack of pipe weld fusion.




Ed developed 4 of the top 10 MIG gas mixes sold in the USA.

The costs of Sales Advice: Weld sales advice often negatively influences the selection of weld 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. Ed developped 4 of the top selling gas mixes used in North America. Cut through the gas product hype that surrounds the 40 plus available gas mixes, and read Eds unique gas mix solutions for manual and mechanized carbon steels, stainless and nickel applications. Weld decision makers should always be able to differentiate practical weld advice from, costly product bias, or sales hype.

If you intend to make a career in the weld industry, this book will ensure
you are on the fast track to optimum weld quality and productivity.

 

The MIG Management Book

"A Management & Engineers Guide to
MIG Welding Quality Costs Training" (656 pages).

Order this Mig Welding Book

If you need all the fine details that go into the exact requirements for all MIG
and flux cored weld applications, take a look at Ed's CD MIG and
flux cored process control training resources.