"A
Management & Engineers Guide to MIG Welding Quality
Costs Training"
656 pages
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Manufacturers,
Fabricators, Weld Quality, Productivity, Costs: When
setting MIG and flux cored welding parameters welders
often "play around" with the wire feed and
volt controls, evident, by the pen or scratch marks
that surround the controls. 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 position 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 clock simplifies parameter selection for any weld.
Tell a welder to MIG welds a 16 gage part with short
circuit transfer, at a wire feed setting of 210 in./min,
140 amps & 17 cups of coffee (17 volts), and watch
the welder smile. Most welding decision makers know
the costs of welding consumables, few welding decision
makers know the costs of their welds. The clock method
simplifies the control of MIG and flux cored welding
quality productivity. The clock method simplifies
controlling welding costs.
Weld Equipment, Pulsed MIG and Invertors: Costly electronic
weld equipment will not compensate for lack of weld
process expertise. Over 100 pages are provided on
why pulsed MIG should not be used or used with caution
for common 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 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 common sense
weld advice based on >35 years MIG expertise.
Robotics:
Over 140 pages of welding solutions to robotic
MIG welding applications are provided. Reduce robot
down time, improve arc starts, eliminate weld spatter,
reduces wire burn back and unnecessary contact tip
replacement. This is the first North American book
that provides advice on how to achieve faster than
traditional weld travel rates. A unique seven step
"Weld Process Control Program" designed
specifically for robot MIG welding cells will assist
the weld decision maker in attaining consistent quality
& productivity.
Automotive
Welding: The North American automotive
industry spends over 200 million dollars each year
on MIG weld rejects and rework. This industry can
anticipate an extensive increase in its MIG welding
problems as it expands its use of extruded thin aluminum,
and strives to MIG weld, thinner, coated, high strength
carbon steels. This book addresses the production
and quality problems, and provides the weld solutions.
Pipe
and Pressure Vessels: Optimum MIG or
flux cored welding procedures are rarely used in pipe
shops. Emphasis is typically placed on the "welder's
skill." SMAW (stick) pipe welding requires extensive
skill and "minimum weld process expertise".
MIG welding on pipe requires "extensive weld
process expertise". Who provides the stick welder
the MIG or flux cored weld process expertise they
need when they change from stick to MIG or flux cored?
Pipe shops often misinterpret lack of "MIG weld
fusion defects" in radiographs. 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 nook provides
unique, MIT pipe welding procedures developed by the
author to minimize lack of pipe weld fusion.
Welding
and Sales Advice: Sales advice often
negatively influences the selection of welding 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.
Cut through the gas product hype that surrounds the
30 plus available gas mixes, and read unique gas mix
solutions for manual and mechanized carbon steels,
stainless and nickel applications. Weld decision makers
should be able to differentiate practical weld advice
from, product bias, or sales hype.
The
Educational Challenge. Many universities,
colleges and trade schools fail when teaching the
MIG and FCAW process expertise that the welding industry
needs. This book would be a valuable asset for these
institutions.
