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Spatter free MIG Short Circuit weld from 1980's Video.
When you combine the optimum weld volts
with the optimum wire feed, the optimum short circuit welding
parameters will produce a crisp, consistent, rapid crackle sound.
The Sweet Sounds of MIG: Today the majority of MIG welders, use arc sounds as a method of fine tuning their weld parameters. Arc sounds are fine but they don't let you know if you are providing the required weld deposition rates.
Welders and robot operators should know "the cause of arc sounds" and the "correct weld parameter weld control response" to those arc sounds".
The weld sweet spot or sweet arc sounds attained with short circuit transfer result when the recommended optimum wire feed and voltage parameters are used. The optimum weld current (wire feed rate) and weld voltage will result in the maximum amount of short circuits achieved each second. The more rapid the short circuit crackle sound the more consistent the "spatter free" weld transfer.
THE ACHILLES HEEL, LACK OF WELD PROCESS EXPERTISE, WELD SPATTER COSTS MILLIONS DAILY:
The welding industry spends millions daily on cleaning welding spatter from its parts. The welding equipment manufactures even build special electronic MIG power sources designed to try to produce minimum weld spatter. The weld reality is this. For the majority of gauge applications, when welding with a low cost, durable, easy to use and easy to repair Lincoln, Miller, ESAB, or Hobart 200-400 amp, CV power source, as this 20 year old video show, set the correct short circuit or spray welding parameters and you will attain minimal weld spatter.
Weld Fact: Remember the key to minimizing short circuit weld spatter is to keep the short circuit weld drop as small as possible and create the fastest rate of short circuit weld transfer. This is achieved working in the recommended SC wire feed range, and ensuring the weld voltage is set to it's minimum. You don't need to invest in a sophisticated Fronius CMT, Lincoln STT or a Miller RMD electronic power source to control weld spatter, you simply use a traditional low cost durable, low cost CV power source and teach the welders or robot personnel to set the correct weld parameters. Most weld spatter occurs with short circuit transfer from a traditional CV power source because the welder has set their weld volts too high.
Your self taught welders may have 20 years of skills experience, however please remember "welding skills are not weld process control expertise" Instead of investing in costly, unnecessary weld equipment which may be impossible for your electricians to repair, or buying loads of anti-spatter, surely its more logical to provide your welders with some process control training.
LETS SEE WE HAVE BEEN BUYING ANTI-SPATTER COMPOUNDS FOR TEN YEARS, AND WE ARE NOW LOOKING AT VERY EXPENSIVE ELECTRONIC MIG WELD EQUIPMENT. WHY WITH A LITTLE WELD PROCESS KNOWLEDGE MY WELDERS COULD STOP PUTTING THAT COSTLY OIL AND WATER ON THE PARTS AND WITH THE MONEY I SAVE, I COULD TRY THAT MINOXIL AND GET SOME HAIR GROWING BACK ON THIS BUSY HEAD.
This picture proudly presented in a USA welding magazine, shows newly trained, Detroit MIG welders welding truck frames. The worst MIG welds found in the industrial world are found on in auto / truck frame plants. The excessive weld sparks seen in the picture, indicate poorly tuned manual MIG welds as evident by the fire works display. The amount of weld spatter generated is excessive and it's evident excessive wire stick outs are being used.
These welders in the photo were trained by a national auto training organization based in Detroit, it's purpose to help auto companies with their weld issues. Obviously the trainers at this Michigan organization placed little emphasis on teaching MIG weld process control.
It's a sad reality also that whenever you find bad manual MIG welds, in the same plant you are sure to find bad robot MIG welds. A Self Teaching, Weld Process Control resource for less than $400 may be the smallest investment we ever make with the largest return.
How many companies are prepared to invest a few pennies per supervisor, robot personnel or welders, for weld process control educational resources or a training program designed to optimize both the manual or robot welding in their organization?
Shoot, it seems the biggest impediment to the implementation of effective Weld Best Practices and Process Controls in my plant is the face that stares back from my mirror.
Most of you reading this weld data will be aware that the welding personnel at your facility are not aware of all of the weld data presented at this site. I have a question for the you, how important is it to your organization to attain MIG or flux cored manual or robot weld process controls? If you think you don't need this type of weld data, do me a favor and try the MIG welding Spray Transfer quiz, and then ask your self how important is this MIG data to your organization?
Consider how easy it is with this unique clock method to bring your weld personnel into a lunch room put my CD in your lap top and project weld data that will optimize the MIG or flux cored welds. Reduce your product liability and eliminate weld rework. Get instant control of your weld costs through optimum weld deposition rates. Get your weld shop into a professional mode with management and weld personnel all walking the same path providing consistent, daily uniform weld results. Become a weld shop that frowns on individuals that play around with the process parameter controls.
HOW YOU CAN USE THE CLOCK METHOD FOR OTHER COMMON WIRES. Welding pipes or structural steels? Do you know the optimum welding parameter range settings for an 0.045 (1.2mm) Alloy Rod E71T-1 flux cored wire, for welding a 1/4 (6mm) fillet weld in the vertical up or over head positions?. What's the single optimum setting for that 1/16 (1.6 mm) flux cored wire? With the clock method its simple and of course flux cored is covered in my books.
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