Item 3 Robot MIG Weld Process Controls and Best Weld Practice Resource:
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Ed developed 7 Steps to Robot Weld Process Controls. With this unique program you can do what he did at numerous global companies. Make one robot produce the same weld production that’s typically attained by most companies that use two robots, and make all the robots attain their maximum weld quality potential.
Above. Em set these Merced es Car Seat Robot Welds in Spain.
When an organization has MIG robots, they often will have a QA team. The question is what real value does the inspection team offer if they only find weld issues after they occur?
In most weld departments, inspection personnel will have received some training in finding and figuring out weld defects. I don’t think in the 1000 companies that I visited, that I met one QA department manager who had ensured his weld Inspectors were trained with the process control expertise that would help the prevention of weld defects. , Imagine how cost effective this approach would be for a company in which weld inspectors primary role, would be to prevent the weld defects rather than just find them.
As many of you are aware, in the global auto – truck industry, the only weld process optimization that comes from controls and best practices seems to occur in the paint department. In contrast you will typically find the daily robot, MIG and resistance weld quality and production often leaves much to be desired. With the auto – truck industry (where the majority of robots are purchased), and industry that spends billions each year on recalls that come from ineffective engineering management, extensive robot weld rejects and rework with unacceptable robot down time is considered normal.
For those managers and engineers that are not satisfied with their weld manufacturing results, and are ready to implement changes for their robot MIG welds, Item. 2. (following) will provide a great opportunity for weld quality – productivity improvements, and of course ensure dramatic weld cost savings:
ROBOT WELD FACTS RARELY DISCUSSED IN THE GLOBAL AUTO INDUSTRY…
[a] The average Robot MIG Weld Production Efficiency is approx. only 40 – 60% of it’s full weld production potential.
[b] The average Robot Weld Rework is typically in the range of 10 to 60%.
[c] If macro examination, or any internal weld evaluation was required on auto – truck robot welds, I out of every three of the robot welds that are at this time accepted, would be rejected due to fusion – undercut – porosity issues..
[d] The average Robot Down Time per-eight hour shift is approx. 30 – 45 minutes.
[e] The majority of manufacturing companies that have purchased MIG welding robots, have never attained the full weld quality and production potential from their robots. Its a sad point to state, but for the last 20 plus years, most of the managers, engineers, supervisors and technicians involved with the MIG welding robots are simply not aware of the robot MIG weld production potential of each robot cell.
[f] The majority of global companies using MIG welding robots, do not have personnel qualified to establish Best Robot Weld Process Controls or Best Weld Practices. The bottom line for more than two decades, the majority of persons that make the robot weld changes each shift, have typically not been qualified to make those weld changes.
[g] There are few plants in which you will find a manufacturing manager, engineers or weld supervisor that can in a few minutes provide you with the real world cost per foot of their most common, robot MIG 3/16 or 1/4 (5 – 6 mm) fillet weld.
[h] More and more welded parts have galvanized or galvanealed coatings. My program provides 10 very effective solutions to reducing the weld porosity, spatter and weld cracks that occur with zinc coatings. With these solutions you don’t need personnel “playing around” with the weld controls and workers doing repairs.
WHEN PROCESS EXPERTISE IS THE MISSING LINK: Many robot MIG applications are initially set by the integrators who sold the robots. The integrator personnel typically will have extensive robot cell build and “programming expertise”, however the employees who establish the welds, will generally lack the MIG, Robot, Weld Process Control and Best Practices expertise. Once these robot cells are delivered, they are too often managed again by personnel who again can operate the robots, but have never received MIG process control training. In these circumstances, it’s understandable that the robots rarely attain their full production and quality potential.
YOU WOULD THINK ANY MANAGER OR ENGINEER, WOULD WANT HIS FACILITY TO BE ABLE TO FULLY CONTROL BOTH THE COSTLY ROBOT EQUIPMENT, AND THE WELD PROCESSES THAT THEY PURCHASED:
Adding to the typical plant’s poor robot weld efficiency, less than optimum weld quality and unnecessary weld costs, is the vast majority of manufacturing managers – engineers who decide which robots and weld equipment to purchase, lack the process expertise necessary to implement robot weld quality and production optimization.
THE MAJORITY OF GLOBAL MIG WELDING ROBOTS UNDERACHIEVE ON THEIR FIRST DAY ON THE JOB,THEN THANKS TO THE UNDER QUALIFIED PERSONNEL THAT DAILY MAKE THE ROBOT CELL WELD CHANGES, THE ROBOT WELD QUALITY – PRODUCTIVITY TYPICALLY REMAINS STAGNANT OR DECLINES.
GLOBAL ROBOT MIG WELD FACT: It’s a reality that the majority of companies who have purchased two or more robots for MIG welds, could with weld process control knowledge produce the same weld production with 30 to 50% less robots.
GLOBAL ROBOT MIG WELD FACTS: The daily logged “Robot Down Time” in many plants is often mostly management fiction, and those manual MIG welders doing the robot weld rework are too often considered by the process ignorant management, as an acceptable part of the costs for the robot welded parts.
GLOBAL ROBOT MIG WELD FACT: In too many plants, once the new robots are installed, unqualified robot weld personnel will daily make unqualified weld process changes to welds that were supposed to be pre-qualified. Lawyers involved in cars and truck crashes should love this liability fact of auto – truck manufacturing.
GLOBAL ROBOT MIG WELD FACTS: The daily never ending weld changes that occur in too many robot MIG weld cells, rarely resolve the daily weld issues and typically add to the weld rework or production problems. In this situation, robot weld production and weld quality usually erodes. For those of you happy with your car or truck robot MIG welds, it’s important to note that few robot welds have internal weld evaluation. If all the welds in plant that utilized robots were looked at internally, it’s my guess, that most plants would have to stop making robot welded parts.
GLOBAL ROBOT MIG WELD FACT: You can count on your fingers and toes the number of global weld personnel that make robot weld decisions and will have the ability to instantly set an optimum pulsed MIG – Short Circuit or Spray weld with any MIG consumables. With this expertise (which is part of this program), robot personnel will have three unique weld transfer modes that allow them to instantly provide a solution to any weld issue, and the ability to instantly optimize the weld quality and productivity with any automated weld or clad weld.
From robot MIG welds in a car or truck plant to robot MIG welds on spent fuel containers for the Nuclear industry. From carbon steels to alloy steels or aluminum. From automated pipe welds to clad welds, this program enables rapid robot weld quality and productivity optimization.
Robot MIG Weld Process Controls and Best Weld Practice Program.
Three items. Item 3 – 3a – 3b.
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Description of Item 3: I developed this Power Point self teaching – training program over two decades. This program took me approx. 3000 hours to produce and its been updated annually. As a training program It will take approx. 14 – 18 classroom training hours to present. For those that do the training, please note, “no robot or MIG weld process control – best practice expertise” is required to present this program.
Irrespective of the carbon steels, low alloy steels, stainless or aluminum, robot applications being welded, this program deals with all the Robot MIG Weld Process Controls – Best Robot Weld Practices necessary to consistently attain optimum robot weld quality and productivity. The program also deals with the primary root causes and resolutions for Robot Down Time, along with the cause and solutions for most Robot Weld Defects. If you have a problem that impacts your robot weld quality – productivity you can call a team meeting and deal with frustration of no one instantly getting to the root cause. Or
you can provide all those involved with robot weld decisions with this resource, and after the training is complete, all on that robot team will walk a single path to instantly resolving those robot MIG weld quality – productivity issues.
PLEASE NOTE. AS WITH ALL MY TRAINING MATERIALS, THE FIRST THING I DO IS” SIMPLIFY THE RESOURCE” SO THAT NO WELD PROCESS CONTROL EXPERTISE IS REQUIRED TO PRESENT THIS PROGRAM TO OTHER PEOPLE.
Please note. I have assisted over a 1000 companies in 13 countries with their weld issues. With the plants that had robot weld issues, I was requested to come to these companies because the major MIG weld equip manufactures such as Lincoln – Miller – Hobart – Panasonic and Motoman, or the major robot integrators and robot manufactures, ABB – Panasonic – Motorman – Fanuc – Cloos – OTC, could not resolve the daily robot weld quality or productivity issues that were being generated by their new robot MIG cells. Typically at these frustrated robot customers, I would quickly reset the robot and weld data, and if requested, I would provide the process control training program (provided here). This program has the information that can enable any plant to consistently attain optimum robot weld quality and productivity.
MANAGERS NOTE: Some managers especially at the major auto companies and there suppliers, actually believe that when they send their operators to go for robot weld training, they were getting the training necessary that enables optimum, robot, MIG weld quality – productivity. Operating a robot is a low skill set, while in contrast programing a robot is a very high skill. Please note, that robot MIG weld process control – best practice training is a completely separate function from robot programming training requirements.
This Robot Weld Process Controls – Best Weld Practice program should be presented to all those weld decision makers that make decisions on the robot welds, and especially those individuals that make the robot weld changes
Jan 2007: Ed. I wanted to send update about that
E-Town DANA plant that you visited a few years ago:
As you know on your first visit to this plant, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour and over 90% required extensive weld rework.
Thanks to your Robot Weld Process Control Training program and your weld process and consumable changes, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.
Many thanks! Ryan Good: A Grateful Engineer and a grateful DANA Corporation.
Note The DANA corporation is a tier one supplier and world leader in the supply of drive line products (axles, drive shafts, and transmissions) and power technologies for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.
E-Mail: Hello Ed. In the past I purchased your MIG welding training resources for both Caterpillar and more recently purchased your Robotic MIG training package for Elgin Sweeper Company here in Illinois. Ed your programs worked wonderfully at Caterpillar. We were very successful after implementing your Best Weld Practices and Process Control Training. Thanks to your resources and equipment and consumable recommendations, our manual and robot MIG weld quality – productivity results are now outstanding. All the best. Joe Cukierski…Weld Manufacturing Engineer.
Elgin Sweeper Company.
It’s questions like this that get resolved with these resources. “With our robots, we have quite a few wire burn backs to the contact tips and these disrupt production. What parameters or practices do I make to resolve burn backs?
|Ed established the original robot MIG Process Control data and Best MIG Weld Practices for the robot MIG welds on the world’s largest trucks.
Ed as you know Tenneco has plants all over the world. We and especially Monroe Shocks which is one of our companies have been very enlightened by your ” Robot MIG Weld Process Control Training Resources.
Regards. Tom Plummer: Tenneco. USA. 2007.
E-mail. Hello Ed, I wanted you to know I have just announced that I am leaving my company. I am now working for a “robot weld integrator”. I will be the head of the welding applications department and will be specifying process, consumables, training, etc. I am very very excited about this opportunity to learn more about welding and to help others to see the light. I hope that we can stay in contact as the years go on. Most importantly, I just want to thank you for the great weld process control information in your books – CDs and your welding passion which you passed on to me.
Warmest Regards. Jeff Winter. Ont. Canada.
OPTIMUM ROBOT MIG WELD QUALITY& PRODUCTIVITY FOR THIN GAUGE PARTS:
From a product liability perspective, it’s ironic that the majority of so called visually acceptable, robot MIG welds, would with an internal, macro weld evaluation, reveal lack of weld fusion or other internal, unacceptable weld defects.
When robot welding thin gage applications, avoiding weld burn through, minimizing distortion and attaining consistent weld fusion with small weld lengths are common issues.
This one of a kind robot weld process control training program provides instant resolutions to all the primary root causes of unacceptable weld quality, weld rework and robot down time.
When robot welding thin gage welds, you can utilize six common weld transfer modes, MIG RMD – MIG CMT – MIG Short Circuit – MIG Globular – MIG Low Spray, or MIG Pulsed. Every time a weld issue occur with one of the weld transfer modes, their is usually a a rework price to pay and a slow or incorrect process action by those involved. Using my program, an organization avoids weld process issues and they will not have personnel “playing around” with the weld data.
OPTIMUM ROBOT MIG DATA FOR PARTS > 3/16 > 5mm.
When Em was asked to establish the robot MIG weld data for the world’s largest trucks, an application that had welds on parts 1/8 to 8 inch thick, he astounded the robot weld engineers when he said “all the welds could be made with three simple settings”.
Keeping robot weld data to a minimum and developing programs that are simple is easy when you know the optimum data necessary for the application, metal. consumables and weld transfer mode.
A few hours with this unique CD program, and your robot weld personnel will have the ability to;
[a] deliver consistent, acceptable weld fusion and weld quality for any application,
[b] provide weld settings that ensure the highest possible weld deposition rates delivering
the fastest possible robot weld speeds.
[c] eliminate robot and weld issues that cause robot down time,
[d] enable the issues responsible for robot weld rework,
[e] provide instant resolutions to all the primary variables that daily impact the robot weld quality or production,
[f] with the implementation of robot best practices – process controls, create a uniform weld shop environment that enables the lowest weld costs and reduces the product liability concerns.
[g] Know when to switch from Pulsed to Short Circ or Spray and provide settings that ensure the highest possible weld quality and productivity.
Ed set the world’s first, multi-robot cell “MIG weld aluminum frame” application. And created millions in annual weld cost savings in this ship yard.
Ed (photo) set the robot, aluminum frame MIG welds on the golf cart(photo) he used to drive around the Aker ship yard where he was the ship yard weld manager. In this Philadelphia ship yard, Ed taught the welders how to optimize their manual – auto flux cored welds used to build Oil Tankers. The annual weld cost savings that he created per oil tanker, was over 6 million dollars.
A FUNDAMENTAL POINT ABOUT MIG PROCESS EXPERTISE. There is a great value to weld process control and best practice knowledge, especially in an organization that annually makes millions of dollars from its welded parts?
The following may be a stupid question that I should not have to ask, yet it’s a question many managers, engineers and supervisors give minimum consideration to. The following MIG weld process control questions should show you there is value in weld process expertise.
If you are a weld manager, engineer, supervisor or technician, and you asked your most experienced robot and weld decision makers the fundamental weld process questions, (link below). And the weld personnel were not aware of the corrects answers, you may want to ask your self this.
“Why has my company invested thousands or millions in robot weld cells and fixtures and we have not provided our employees with the necessary robot weld process control – best practice training”?
It’s questions like this that get resolved with these resources.”Ed, most of our robot short circuit and pulsed MIG welds are only 1 to 2 inch (25 – 50mm) in length. After weld macro examinations, we find either lack of fusion or poor fusion in the first 12 to 15 mm of the short welds. What robot weld changes can we make to improve the integrity of the weld starts”?
MIG ACCOUNTS FOR 80% OF THE GLOBAL WELDS PRODUCED DAILY:
For those of you that wonder about the level of their MIG weld process knowledge, try this. Ed’s MIG Weld Test.
It’s questions like this that get resolved with these resources. “We have many robot arc start issues, and there is a ball of metal on the wire tip at the weld ends. What adjustments can i change to solve this problem”?
ROBOTS ENABLE FASTER WELD SPEEDS THAN THAT POSSIBLE BY A MANUAL WELDER, YET MAXIMUM WELD SPEEDS WILL RARELY BE ATTAINED WITHOUT THE PROGRAMMER HAVING WELD PROCESS CONTROL – BEST PRACTICE EXPERTISE.
I was the first person in North America to develop extraordinary MIG weld deposition rates of 15 – 25 lb/hr for common MIG gage and heavy wall robot and automated applications. I included the unique high dep weld data in my Management Engineers Guide to MIG, (item 1). Higher MIG depositions enable dramatic increases in robot weld speeds on gage parts and create much lower weld costs on thicker parts. I also developed a patent for MIG high deposition, Cu – Ceramic CONTACT TIPS that were designed for increased robot – automated weld speeds in the range of 60 – 100 inch/min on gage parts. For the power industry, I developed a high deposition, (15 – 20 lb/hr) pulsed MIG patent for inconel / stainless, single pass, clad welds on global water wall boilers.
INSTANT ROBOT WELD BENEFITS:
It’ this simple, bring all your weld decision makers to a training room. Place my CD power point program in a laptop. Project the program to the screen. In a few hours everyone has the necessary robot MIG data to establish Best Weld Practices and implement Weld Process Controls.
As the Genie and Sky Trak plants found out with their lifting equipment, (shown right), with Ed’s manual and robot process control training programs, optimum MIG weld results were immediate and the weld cost benefits were extensive.
THIS PROGRAM ALSO CUTS THROUGH THE TOO COMMON GLOBAL BS AND MYTHS THAT DAILY INFLUENCE THE CHOICE OF ROBOTS, WELD EQUIPMENT AND CONSUMABLES. IT’S ESPECIALLY BENEFICIAL, IF YOU WANT TO GET AWAY FROM THE PURCHASE OF THE OVERPRICED, EQUIPMENT WITH USELESS, ELECTRONIC BELLS AND WHISTLES, THOSE RIDICULOUS THREE PART GAS MIXES, AND THE COSTLY, UNNECESSARY CONSUMABLES THAT ARE PART OF MANY WELD SHOP.
It’s questions like this one that get resolved with these resources.
Our robot, pulsed gauge welds are only 2 to 3 inch (50 to 75 mm) in length. The problem is the last 5/8 to 3/4, (15 to 18 mm) of each weld length. The welds typically get narrower with a crater appearance. What can I do to change the robot data to resolve this?
Ed in a robot cell demonstrating how useless the Miller weld equipment bells and whistles were to the employees at VIZA. This company is located in a town called Vigo in Spain. Viza is one of the largest car seat manufactures in Europe.
At Viza, Ed was hired to optimize the robot weld quality – productivity. In the photo on the left Ed was educating their managers / engineers on what a waste of time and money it was to purchase the the so called sophisticated, Miller Axcess Power source with it’s Palm Pilot Parameter Controls, (shown in photo)… Viza made car seats for Mercedes, VW and Citroen.
Years previously at Viza Ed was asked to select the robots and weld equipment to get Viza into the automation age. He recommended they purchase the less costly, superior performing Miller Delta Weld equipment and ABB robots. With this equipment and with Ed’s Robot Process Control – Best Practice Training Program, Viza had the keys necessary to provide the highest possible weld quality with the desired production at the lowest possible weld costs. Viza grew rapidly into an outstanding European tier one car seat supplier. .
The robot process control – best practice training program which was given to VIZA robot team, is applicable to anyone in a plant who has an opinion or makes decisions on robot weld quality or productivity. Managers, engineers, supervisors, maintenance, QA personnel, robot technicians and operators who make weld changes, all should walk the same path to robot weld process optimization.
Note: If you have robot programming expertise and would like to move forward in your career, pick up this CD, learn the contents and with great confidence you will know you are ready to establish optimum weld automation with any global company on any robot application.
Photo from Smithsonian Magazine.
One of Ed’s major robot TIG projects, were complex robot TIG welds on the critical components for world’s largest solar farm. the Ivanpah project. These welds were the robot brkt – tube welds, (tower collector vessel welds that receives the rays). These were complex alloy welds on thin parts. The 3500 acre solar farm will produce approx. 392 megawatts. This project cost more than 2.2 billion dollars. The farm has approx. 173,000 mirrors and each 70 sq/ft mirror reflects the sun to a focal collector point on the tower shown. The suns energy will create enough power for 140,000 California homes.
The brkt welds that hold the collector vessels that absorb all that sun’s energy were very difficult robot TIG welds made with extraordinary weld quality demands. The demands were made unnecessary complex by designers, engineers and managers who did not understand weld processes and robot welds. Ed provided most of the weld process controls and best practices that were necessary to overcome the weld complexities on these critical welds.
It’s questions like this that get resolved with these resources.
Ed, we keep getting concave craters at the robot weld ends, and sometimes the
craters have small cracks. What robot weld parameters or techniques can we do to fix this.
I love reading historical fiction about the religious wars that occurred over the last 2000 years between the Muslins and the Christians. My question today is a simple one, with all the issues in the middle east, what the hell has happened to human evolution? And then of course my next question would be, “what the hell has happened to weld shop evolution? .. E Craig. 2013.
Ed, with the robot weld data we use, many of the welds are fine, however we do get quite a few welds that burn through. What robot best practices can i use to minimize weld burn through?
Ed, most of our gauge robot MIG welds are done at weld speeds between 30 – 50 inch/min (75 – 125 cm/min).
My boss was asking if there was any way to to speed up these welds. He wants 20 – 25% more weld production each shift
It’s questions like this that will get resolved with these process control – best practice self teaching – training resources.
Ed. I just received your process control materials and within five minutes of skimming through your materials I found flaws in our exhaust weld shop practices and techniques. We were not using logical process controls and your materials will be very helpful to our organization! Ed thanks for sharing your expertise and the prompt delivery of the materials.
Marcus di Sabella. Process Engineer.
Car Sound Exhaust System, Inc. – Magnaflow.
Performance Exhaust. Rancho Santa Margarita, CA.
Ed. Your process control training resources are fantastic for anybody engaged in weld engineering. They are simply priceless and I am committed to learn them in totality and applying the process knowledge successfully. I shall owe my success to you forever. In case you come out with something new kindly let us know. Thank you very much. Sudip K Haldar. Pari Robots. India.
E-mail. Ed. I work as manufacturing engineer in Johnson Controls Alagon (Spain). We mainly build car seat structures, I believe you set the Johnson control VW Beetle car seats in Mexico and the results were outstanding. Last week I received your robot process control material, which I’ve been reviewing. I find it your program very cost effective and practical. Your approach to weld process control is unique and it certainly works. In reading your materials, it seems like you have been in our company as most of the issues you address and resolve are part of our every day work. Thank you Jose Ignacio Moreno. Spain.
Ed, we are having robot weld fusion and porosity issues with some of our pulsed MIG stainless 3/8 fillet welds. Are there best weld practices we could use to resolve the weld issues”?
It’s questions like this that get resolved with these resources.
There are numerous weld issues that occur daily in robot cells, however I am sure that after the 3000 hours that it’s taken me to develop this program, I believe that I have provided soulutions for 99% of the common robot cell weld problems.
The Self Teaching MIG Book.
“Manual – Robot MIG Weld Process Control Simplification”.
Written by E Craig. (170 pages).
This is a “self teaching” Manual and Robot MIG Weld Process Control, Training book. This book is an essential tool for MIG weld quality / productivity optimization. With this book you will learn Ed’s unique, weld process control “Clock Method” which provides a simple, highly effective, easy to remember approach to the selection of optimum MIG parameters for any manual – robot carbon steels, alloy steels and stainless applications. Answer the 160 questions and you are ready to present the robot process control training program.
It’s questions like this that get resolved with these resources. “Many of our robot welded parts have both weld fusion and weld distortion concerns. If we turn up the weld heat to improve the fusion, we add to the distortion. We need either parameter or best practice solution to resolve the problems”?
The DVD Video.
“Manual MIG Process Controls Made Simple”.
Produced by E Craig. (Runs 60 minutes).
When training, a good video is always worth a million words. This DVD is a great visual tool in the presentation of the simplification of the selection of optimum, CV MIG parameters, for all those manual steel and stainless applications.
This unique MIG training DVD has been purchased by hundreds of companies in 14 different countries. Companies such as GM, Caterpillar, Case, Ford, Volvo, Tower Automotive, Magna, Dana, ABB, Babcock, Boeing, Delphi, TRW, Monroe, Johnson Controls, Textron, Genesis, General Dynamics, General Electric and numerous others.
Ed took over 2000 hours to develop this unique, Robot Process Control Training Program.
Questions?., Call Ed. 828 337 2695. E-Mail email@example.com.
To order click here.
Item 4 Description of The Management – Engineers MIG book:
Note with this order you get to choose an above training program.
To Order Click Here.
“A Management & Engineers Guide To MIG – Flux Cored,
Weld Quality – Productivity and Costs”
Perhaps you wish to change that too common “play around” with the weld control approach to MIG and flux cored welds. Or maybe you are fed up with hearing, “why change the way we have always done it”. Maybe you want to get away from being influenced by weld equipment, consumable sales reps. Possibly you wish you had a better understanding of the MIG and Flux Cored weld costs. Or you want to know how to optimize the MIG and Flux Cored weld production and quality. The bottom line is you are likely an individual that likely believes in the importance of taking ownership of the weld process, equipment and consumables that have a key role in both your career and companies’s profits.
This book was written by E Craig, With 600 pages. It’s the most comprehensive book ever written on the weld management – engineer requirements necessary to consistently attain the highest MIG – Flux Cored weld quality – productivity at the lowest possible weld costs.
Note. This book and the Process Control training program, reveal the importance of Process Control expertise and implementing Best Weld Practices. There are many weld cost benefits attained from weld personnel that can fully control and optimize the performance of the weld Process and consumables utilized on any applications. Please do not confuse weld experience / weld skills with weld process control expertise. If you think your weld personnel have the weld expertise necessary to optimize the common MIG or Flux Cored welds, ask the best welders in your facility the following simple weld question.
I’m reading your Weld Management – Engineers Guide book, and by the way it’s the best Welding Reference book that I have ever bought! Since the book was written a few years ago, what in 2016 is your best choice for welding wires for GMAW and FCAW carbon and stainless steels?
Thanks. SO. Quebec. Canada..
Answer: Steve ref my weld consumables and weld equipment recommendations, nothing has changed in 2016 from the recommendations I provided in my books and materials, except of course today we have more unnecessary BS consumable weld claims and more weld equip with costly useless Bells and Whistles.
Question: You want to make a carbon steel MIG fillet weld on a 1/8, (3.2mm) to a 1/4, (6.4mm) plate. You have a common 0.035 or 0.045 (1 – 1.2mm) MIG wire with an argon 15 – 20% CO2 mix. An experienced weld decision maker would be aware that a good weld mode start point for this weld would be to set the wire feed and voltage at the start point of spray transfer. What is the MIG spray transfer start voltage and wire feed rate, (inch/min or m/min), that is required for the world’s most common, 0.035 – 0.045 (0.9 – 1.2mm) MIG wires. If you ask five weld personnel in the weld shop the above fundament MIG question, you will likely get five very different answers, and most of the answers will be incorrect.
E-mail.2007: Ref the Weld Management Book:
Hello Ed. I recently purchased your “Management and Engineers Guide to MIG Welding”. The book and CD training program was everything I had hoped they would be and then some! Thanks Ed for having the motivation and courage for your web site and the information you provide. I have not yet come across an opinion that I did not share or a concept I did not admire. ”The more I learn from you, the more I find there is to learn.” Cutting through the BS and producing the best possible welds at the lowest costs, is what makes learning your Clock Weld Method exciting. Your weld process knowledge combined with your personal opinions (which I find, hit the nail on the head every time) has made these resources one of the best weld shop, and training tools I have seen to date. Worth much more than you charge.
Thanks a million Ed. Regards. Fraser Rock.
Ed. I received your “A Management & Engineers Guide to MIG” and the training CD. Thanks a million Ed. I am pleased to learn about MIG and Flux Cored welding. I am 33 years old from north-east Italy. I work as a mechanical designer in a company that designs and manufactures rolling mills all around the world. All the welded structures built are heavy parts made in carbon steel plates, welded almost always by multi pass manual MIG welding. The engineers and project managers in our technical office spend a lot of money and time buying expensive weld calculation software and complying to the confusing ISO-EN standards, then we have the advice of the so called weld consultants and weld associations. The bottom line is most of us have had absolutely no idea about how the MIG process works or how to recognize a good or bad weld procedure. With your book I finally have found a logical solution to understanding and controlling the MIG process.
Regards. Oscar Cavezzan Italy.
Another benefit of weld process control education.
WELD COSTS – WELD QUOTES – WELD COSTS – WELD QUOTES – WELD COSTS – WELD..
Understanding and quickly working out weld costs, is an important management, engineering and supervision function. All my programs simplify this subject.
Real MIG – Flux Cored weld costs is a subject that’s rarely discussed in most weld shops, however in the front office, there is typically frequent discussion about the costs of the MIG weld gases and the weld wires. While weld consumables typically are no more than 20% of the cost of MIG or FCA welds, there is usually minimal conversation on the real costs of the common welds produced in the weld shop.
If the prime weld decision makers in a weld shop, are not aware of the real costs of their common MIG or Flux Cored fillet welds, how can that weld shop control it’s weld costs, or how can that company optimize it’s profits?
In the front office of any weld shop, there should never be a mystery with the costs of the common welds that are daily produced in the weld department.
The most common, global MIG or Flux Cored steels and alloy steel welds, are 5/16 – 1/4 – 3/16, (8 – 6 – 5 mm) fillet welds,. In the hundreds of weld shops that I provided weld optimization for over a 5 decade period, if I was to ask the key weld decision makers in the shop, who were aware of the weld costs per-foot or per-meter, of their common 1/4 (6.4 mm) steel MIG or Flux Cored fillet welds? I am sad to say, that I never met one individual who could quickly provide the correct answer.
I believe that many in the weld industry would agree with me that it’s rare to find a weld manager, supervisor or technician that can provide a simple cost calculation for their common daily welds. The unique, MIG – Flux Cored weld process controls and best practice weld resources that are provided below, simplify working out the costs of any MIG or Flux Cored weld. The bottom line, any weld decision maker should have the ability with a glance at the wire feeder, to be able to within a couple of minutes, to work out the shop’s real costs of that MIG or Flux Cored weld.
When the majority of global weld shops focuses on the welder’s skills, rather than on the weld process control expertise, you know something is not quite right.
For decades, while the majority of the global MIG – Flux Cored welders “played around” with their weld controls, the majority of weld industry managers and supervisors placed their focus on their welder’s skills and their length of weld experience. The sad reality is minimal focus was placed on the weld Process Controls – Best Practice expertise available with the personnel in the weld shop and just as important with the personnel in the front office.
THIS LONE VOICE IN THE WELD INDUSTRY WILDERNESS, HAS BEEN STATING;
“That without MIG – Flux Cored weld process control expertise, and the implementation of Best Weld Practices, it’s impossible for any weld shop to consistently attain optimum MIG – Flux Cored weld quality and productivity, always at the lowest possible weld costs”
Too many managers in large companies, love to waste money on pulsed
MIG weld equipment and it’s useless electronic bells & whistles.
Many global companies pay a huge price for weld management process ignorance,
it’s ironic in 2014, that in Asia, where weld labor costs are typically miniscule, that you will find the majority of large weld – fabrication companies are demanding very expensive Chinese made pulsed MIG equipment. The sophisticated electronic, Pulsed MIG equipment typically costs $6,000 to $15,000. It’s a weld reality that In 2014, as it’s been for at least 25 years, most of the weld shop managers who make the Pulsed MIG equipment purchase decisions, are rarely aware that the sophisticated, pulsed equipment, will in contrast to a $3,000 to $4000, well made, regular CV, MIG power source, will result in the following:
Please note that with most MIG fillet welds, that weld fusion is typically marginal, and the prime purpose of any weld is to provide consistent, optimum weld fusion..
[a] The costly, pulsed MIG units will on most welded parts > 2.5 mm, produce welds with less weld fusion and welds with more porosity than spray welds made with the much lower cost CV MIG equipment. The reason for the pulsed MIG weld fusion and porosity concerns is a simple one. The pulsed MIG welds spends 50% of their arc on time, with a pulsed back ground weld current of less than 100 amps.
In contrast to the traditional, open arc, spray weld from a low cost Constant Voltage MIG unit, It’s logical that any pulsed weld will put in less weld energy. For those that want proof, it takes five minutes. First make sure your weld personnel are trained to set optimum MIG spray settings with a CV MIG power source. (if they can’t answer the MIG weld questions at the top of the page, they are not trained). Have the welders produce a single pass, 1/4, 6 mm, horizontal, spray fillet weld. Section both welds in the middle, and examine the weld fusion and porosity in both the Pulsed & the Spray weld cross sections.
[b] A key characteristic of a Pulsed MIG weld, is with the “lower open arc weld energy potential” than a conventional MIG spray weld,the pulsed mode will benefit specific, limited, manual, heat sensitive applications such as weld cladding (require low weld dilution) and thin heat sensitive, < 3 mm aluminum welds. Pulsed MIG benefits are also attained with automatedall position, pipe welds, in which the MIG wire stick out, the weld travel speeds, and the weld weaves are controlled. The weld shop reality however is that 99% of all manual MIG welds, will with low cost argon 2 - 20% CO2 mixes, achieve the highest possible weld quality, (with minimal spatter) at the lowest possible weld costs. However the MIG spray welds, will rarely be attained by weld personnel that play around with their weld controls. To optimize MIG - FCA weld quality - productivity has never required sophisticated MIG equipment or three part gas mixes, theses welds simply need to be made by individuals who have received training in MIG - FCA weld process controls and best weld practices.
Most weld sales and MIG equipment reps, either don't know, or they don't want their customers to know, that the highest MIG weld quality and productivity, can be made by the lowest cost MIG equipment and two part gas mixes.
That costly weld application qualification typically means little with the pulsed MIG process. By the way, I hope you have considered the fact that each new pulsed MIG unit bought into the plant should typically require a new, costly, weld re-qualification of your existing weld procedures. (not a concern with CV equipment and spray - short circuit welds) The reason for the re-qualification, every new model of pulsed MIG equipment will typically will have major electronic changes, and for a given wire feed rate the pulsed output changes could dramatically impact the weld variables and weld energy produced. The bottom line is this. If for example your company spent thousands of dollars on a pulsed MIG weld application qualification 5 yrs ago, and then purchased new pulsed MIG equipment today, your company would from possibly a weld code requirement or from a knowledgable weld engineer's perspective need to re-qualify the welds and create new procedures. Not re-qualifying the pulsed weld with the new pulsed equipment, is just another one of those weld shop concerns that one day will have dramatic weld cost liability consequences for some companies.
[c] That new, overpriced pulsed MIG weld equipment will in many instances rarely get through it's short warranty period without circuit board issues that will likely impact your companies weld quality - productivity. When the pulsed unit does require repairs, expect to pay thousands of dollars, and pray it wont take more than a month or two to repair. Please also be aware that your organization added to the pulsed equipment longevity and durability concerns when the pulsed equipment purchased was made in China. With Chinese pulsed MIG units I believe you should expect extensive costly repair and weld performance and weld quality issues. In contrast, that low cost, regular, USA made MIG equipment should typically be in weld shop service, without requiring repairs, for 10 to 25 years. Also note most electricians should have the ability to repair regular CV equipment at low costs.
I have evaluated global pulsed MIG equipment for approx three decades. There are THOUSANDS of words I've written on pulsed MIG weld - equipment issues in the pulsed MIG, and MIG Equipment Evaluation sections at this site. Also I have written over 100 pages in, "My Management - Engineers Guide To MIG" book, on what's wrong with the Pulsed MIG process, and of course the subject is covered well in my manual -Process Control training programs, which by the way also tell those that have purchased pulsed MIG units, how to get the best weld quality - productivity out of that pulsed equipment.
It's a sad reality, that in the weld industry, that the most widely utilized MIG process has for decades been surrounded by confusion, and that the only companies that usually benefit from the more costly pulsed MIG equipment sales, are the companies that make and sell the pulsed MIG units.
The reason managers and engineers around the globe, buy into the pulsed hype is the too common weld shop reliance on salesmanship for MIG weld equipment advice, and also of course, the general weld process control - best practices ignorance. So those of you making MIG equipment budget decisions, instead of wasting thousands of dollar in the purchase of pulsed MIG units, I would recommend the weld shop purchase of a well made USA Miller - Lincoln. CV $3,000 - $4,000, 350 - 450 CV MIG power source, (Miller Delta Welds lead the way). If selecting European, CV MIG equipment, consider ESAB, CV units. To get the best out of this lower cost equipment, you will need then to spend a whopping $400 on my MIG or Flux Cored Weld Process Controls - Best Weld Practices resources. If the person who is in charge of welding can read a power point program, they are qualified to do the training with these unique, easy to teach resources.
Management needs to be aware of the important relationship between Weld Process Control Expertise - Best Weld Practices, with the attainment of consistent, optimum weld quality - productivity, at the lowest possible weld costs
The weld industry is unusual in that it's a high tech industry in which the majority of weld personnel have for decades played around with the two primary weld controls. In these circumstances, an industry has been created in which too many weld decision makers rely on sales advice and lack in-depth weld process control - best practice expertise. Instead of watching a manual welder or robot programmer "play around" with their MIG or flux cored weld controls, consider the benefits of trained weld personnel who are provided with MIG weld process and best practice expertise. Those manual welders, will always provide optimum weld settings that produce the best possible weld quality, always with the highest weld deposition rates. And those trained robot programmers could instantly set the data on any dumb, blind robot that's attached to a low cost, CV, MIG power source, and consistently produce the highest possible robot weld quality and productivity.
When you purchase the following MIG and Flux Cored weld process control resources, you are purchasing programs that I developed over five decades. These easy to learn and easy to teach training resources are updated frequently..
When the major robot companies and MIG power source manufacturers failed to optimize the robot weld quality - productivity with some of their important customers, the following are a just a few of the robot weld applications in which I was asked to resolve weld quality - productivity issues:
FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES - HARLEY BIKE FRAMES - INDIAN BIKE WELDS - NEW VW BEETLES & MERCEDES CAR SEATS -WORLD'S LARGEST CATERPILLAR TRUCKS - I WAS THE FIRST PERSON IN THE WORLD TO SET ROBOT WELDS ON DIFFICULT, POWER PLANT, BOILER TUBES TO HEADER WELDS - ALSO THE FIRST TO SET ROBOT CLAD WELDS INSIDE BOILER WATER WALLS - FIRST TO SET ROBOT WELDS ON A 40 inch PIPE - FIRST TO SET ROBOT WELDS ON AN OIL RIG - FIRST TO SET MULTI-ROBOTS IN A WELD CELL WELDING LARGE ALUMINUM APPLICATIONS.
One good thing with MIG or Flux Cored weld issues. If someone in the company has weld Process Control expertise, they should have the ability to provide instant weld resolutions, and create dramatic weld cost reductions. Then with the implementation of best weld practices, they can ensure the weld issues do not occur again:
If you have worked in a weld shop that uses MIG – FCAW, you may have watched weld personnel “play around” with the MIG power source controls, which have hardly changed since the 1950s. In the play around weld shops, consistent optimum weld quality is rare, as is attaining the highest weld productivity with welds at the lowest costs.
If you have worked in a weld shop, you may have often seen, those unqualified, weld sales reps, providing weld advice to the weld shop supervisors and managers.
You may have been in the weld industry for decades. I would like you to think back and see if you can recall any weld decision maker that could look glance over at a the MIG wire feed control, and the weld arc, and then in less than three minutes tell you the real costs of the weld being produced. I believe that most weld shops, the management weld shop cost focus has usually been on the costs of the MIG – FCAW consumables which typically account for less than 18% of the total weld costs.
If you have worked in a weld shop, you must have wondered why the lack of MIG weld equipment uniformity. Why is the shop always trying different weld equipment, wires and gas mixes? Why are there more than two MIG gas mixes in the cylinder rack? (Any plant that uses more than two gas mixes for traditional steel and alloy steels applications, sends a message that they are not in control of the weld shop). Why also are there so many weld consumable sizes and types? and does the weld shop really need those costly Metal Cored and Flux Cored weld wires?
Managers should consider, how cost effective is it to put welds on the parts then grind the welds off?
If you worked in a weld shop, you must have wondered how much money was spent each year on the purchase of unnecessary grinding wheels and wire brushes, and how much weld shop labor costs were wasted daily on unnecessary grinding, unnecessary weld cleaning and unnecessary weld rework.
If you worked in a weld shop, you must have met weld Quality – Inspection personnel that waste hours discussing weld defects, and you may have thought it unfortunate that these guys lacked the weld process knowledge and ability to prevent the weld defects from occurring
These weld process controls – best practice programs, will provide anyone with important weld information that is not available at any global university or college that provides either weld engineering or welder training programs.
When anyone in this industry gives themselves the ability to instantly create dramatic, weld quality improvements and weld cost savings, their weld career prospects should be unlimited, especially when working in an industry in which MIG – Flux Cored weld process controls and best weld practices will for years be rare.
PLEASE NOTE: I established www.weldreality.com in 1997, this was before Google was a company. In the 1990s web site building technology was crude, and my web site expertise, and control of the English language was, and still is laughable. This site may not be a sophisticated looking, however it’s a site full of practical, real world weld information based on the 50 years I’ve spent in this business.
2017.. Please note in an industry guided by salesmanship, I have accepted advertisements, for which I paid a steep price in my search engine optimization. The bottom line is this. I am aware that at this site where there are well over millions of words, that you will find many typo errors, and the web format style will look forever look dated, however I don’t really care. I simply write the way I think and speak, and I always try to avoid BS. I m proud of the fact, that for the last 20 years, this site has been the world’s largest and most practical MIG – Flux Cored – TIG web site on Best Weld Practices – Weld Process Controls. You may get tired of reading this stuff, however, I will never get tired writing it. Thank you for reading. Regards Ed Craig
If the weld industry employed personnel with MIG weld process control expertise, and all the costly pulsed MIG equipment, three part gas mixes, and metal cored wires were pulled from the global weld shops, the bottom line would be that there would be no negative impact on the weld quality and productivity. It typically takes me or the people I have trained about 30 minutes to prove this point. This is something I have proven in hundreds of weld shops in thirteen countries.
As few sales reps have ever managed a weld shop, why would any weld professional want weld advice from a sales rep?The 1970s, was the time when weld managers, engineers, supervisors and technicians should have stopped listening to the mostly unqualified, too often biased weld sales advice that inundates the global weld industry. Fifty years later, in the majority of global weld shops you will still find the same sales influence, the same process confusion and the same daily weld BS. This industry, will I believe, get the respect it deserves, when the key weld decision makers cut the umbilical cords attached between themselves, and the companies that make and sell weld equipment and consumables.
Weld Quality – and Weld Costs Benefits are readily attained when weld shop management, engineers and supervisors actually take ownership and responsibility for the weld processes – and weld equipment that daily creates the profits for their organizations.
The Manual MIG, Flux cored, Robot MIG and Advanced GTAW Training Programs are available with the Management book,
MIG – Flux Cored – GTAW weld process control – best weld practice expertise, open the doors to increased company profits, & also improves weld career prospects.
WELD PROCESS CONTROL – BEST PRACTICE TRAINING AT YOUR FACILITY?
Their are two ways to get my manual – robot MIG and flux cored and TIP TIG weld Process Control – Best Weld Practice Training or Self Teaching Programs.
 You can order one of my programs,
 You can request my customized training program at my place in Asheville NC, or at your facility.
One Popular Seminar I provide for large companies.
” HOW TO MANAGE A WELD SHOP & ENSURE MAXIMUM DAILY MANUAL – ROBOT
WELD QUALITY AND PRODUCTION, ALWAYS AT THE LOWEST WELD COSTS”.
MY CUSTOMIZED TRAINING PROGRAM FOR YOUR WELD SHOPS.:
The following customized MIG & flux cored, Weld Process Control & Best Weld Practicetraining program is suited for managers, engineers, supervisors, technicians, QA personnel and welder trainers.
In the competitive global weld – fab industry, increased profits will be achieved by those companies that employ weld decision makers that do not have to rely on weld sales advice, and have the Weld Process Controls and Best Weld Practice capability for weld process optimization in their organization.
PROCESS TRAINING & WELD COST REDUCTION OPPORTUNITIES FOR YOUR COMPANY:
Extensive weld cost savings will be found in any weld department in which manual weld personnel and robot technicians no longer have to play around with their MIG and flux cored weld controls.
Extensive weld cost savings are generated in weld departments when weld processes, weld consumables, weld transfer modes, weld deposition potential and weld costs are understood by the weld decision makers.
Extensive weld cost savings will be generated when the manual / robot weld quality is consistently optimized, weld rejects and rework are reduced, and the prevention of weld defects is understood.
Extensive MIG weld equipment and consumables cost reductions are enabled in weld departments in which the weld decision makers no longer rely on weld sales reps for weld advice. These cost benefits will be many;
 The weld decision maker will have the reasons and proof that your company does not need to purchase costly pulsed MIG equipment that’s typically loaded with useless electronic bells and whistles.
 The weld decision maker will no longer need to purchase three part gas mixes or a variety of different gas mixes.
 The weld decision maker will not require the costly metal cored wires and will think twice about the flux cored wires purchased.
 The weld decision maker will dramatically reduce weld fumes and weld grinding enabling a cleaner safer environment and also reduce the requirements for grinding wheels & discs.
A QUALIFIED MANAGER WOULD BE AWARE THAT IT DOES NOT NEED A WELD TEAM TO RESOLVE ANY MANUAL – ROBOTS WELD ISSUES, IT SIMPLY REQUIRES ONE QUALIFIED INDIVIDUAL WHO CAN THEN TRAIN THOSE THAT ARE INVOLVED WITH WELD DECISIONS.
My customized programs typically last one to two days and i will also instantly resolve any weld issues you have in the plants and provide optimum procedures. Any participants will in a few hours become manual or robot MIG – FCA weld process controls experts.
For more info. E Craig. 828 337 2695. E-Mail firstname.lastname@example.org.
THE VALUE OF MIG WELD PROCESS CONTROL – BEST PRACTICE
TRAINING IN THE AUTO – TRUCK INDUSTRY:
E-Mail. Ed I wanted to send update about that E-Town, DANA plant
that you visited a few years ago. As you know on your first visit, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour, and over 90% of the frames required extensive weld rework.
Thanks to your Robot Weld Process Controls – Best Practices Training program, and your process and consumable recommendations, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.
Many thanks! Ryan Good.
A grateful engineer, and a grateful DANA Corporation.
Note The DANA corporation is a tier one supplier and a world leader in the supply of drive line products such as frames, axles, drive shafts, and transmissions for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.
WELD PROCESS CONTROL TRAINING FOR ANY WELD SHOP USING MIG – FCAW.
E-Mail. Dear Ed, I want to let you know that by using your MIG – Flux Cored weld process control – best practice methods in our plants, we have now dramatically improved our weld quality – productivity and reduced our labor – filler metal costs by approx. 45%. We intend to utilize your training program in all our plants.
Lawrence Bower CWI/CWE.
Chief Welding Engineer.
NCI Group. Houston TX.
Mangers, please be aware that Universities, Colleges & Training Facilities, don’t provide the weld industry with the weld process control – best weld practice resources that are provided here. If you feel you are on top of your processes try the following weld quiz.
Ed’s MIG Weld Process Controls & Best Practice Quiz.
Ed’s Flux Cored Weld Process Control & Best Weld Practice Test.
Home Page weldreality.
To order click here.
FOR THOSE LOOKING TO HIRE MIG – FLUX CORED WELDERS, PLEASE NOTE THE SO CALLED “SHORTAGE OF SKILLED FLUX CORED, TIG AND MIG WELDERS” HAS FOR AT LEAST A DECADE SIMPLY BEEN WELD FICTION..
Many global managers believe there is a so called shortage of skilled MIG, TIG and Flux Cored welders. The reality is this. Once any company provides the unique best practices – process control training programs at this site, with less than FORTY HOURS of hands on training, irrespective of the weld skills or lack of weld experience, all the personnel taking the training will have the ability to instantly set optimum weld parameters and to attain without “playing around”, uniform, consistent, optimum MIG – TIG or Flux Cored welds on any application, and that includes all code quality welds.
Questions call Ed. 828 337 2695.
E Mail email@example.com