Written by Ed Craig. This is the world's largest web site / blog
on manual - automated, MIG - TIG - Flux Cored, Best Weld Practices and Weld Process Controls.
Please refresh this page as it's updated frequently.
Contact. Email email@example.com.
Weldreality Home Page. 1.
This web site / blog was started in 1998 by
Ed Craig. www.weldreality.com ©.
What you will find at this home page.
 An introduction to TiP TiG.
 There will be weld issues at the Bejing Olympic stadium.
 Why is the weld industry wasting money on useless electronic bells and whistles?
 Why the concern for the so called shortage of skilled welders.
 The consequences of hands off management.
 Is the weld shop run by a firemen or weld manager?
 How important is fundamental weld process control expertise to your organization?
 Where are the qualified weld managers?
 Never ask a designer of a welded part, a weld question.
 For the first time, Ford and Dana engineers saw optimum robot frame welds.
 There are more than sixty MIG gas mixes available, yet the global weld industry only needs four.
name is Ed Craig. Many
of you will know me from the 18 years I wrote the QA weld column in the USA Weld
Design and Fabrication magazine or perhaps you read one of my thirty published
articles on the simplification of manual and automated MIG and Flux cored weld process controls. If you have a Machinery Handbook gathering
dust on you shelve and its not too old, I wrote the weld section. I have written three books on MIG and FCA weld
process controls and with forty five plus years of hands on weld process control expertise, I have resolved
manual and automated weld issues in more than a thousand companies in thirteen different
hope you enjoy weldreality.com and it's focus on MIG, TIG and flux cored, Best Weld Practices
and Weld Process Controls:
To examine the extensive programs at this look to the links on the left and visit all programs.
WHEN YOU WISH TO CONSISTENTLY PRODUCE THE HIGHEST POSSIBLE CODE QUALITY, MANUAL AND AUTOMATED WELDS,
THERE IS ONLY ONE WELD PROCESS AND IT'S CALLED TIP TIG.
In 2009 I was in Europe helping Cameron a subsea valve manufacture with their automated Hot Wire TIG clad welds. While in the UK I heard about a unique weld process called TIP TIG, and with my business partner we bought this process to
When you visit www.tiptigusa.com you will find that TIP TIG is the natural evolution of the seventy year old TIG process. This process delivers 100 - 400% more hourly production than regular TIG, is easier to use than TIG, and attains superior weld quality than any other weld process. If you weld alloys this process also delivers the lowest possible weld heat and the least possible weld fumes. So after 40 years of optimizing MIG and flux cored welds, and 30 years of wasting time
with the manual pulsed MIG process, instead of early retirement, I am now trying to keep out of my wife's way and ensure
North - South America and Australia becomes aware of the TIP TIG process.
2009. Have you seen the patent pending TIP TIG process.
This is the first,
practical manual - automated advance in North American
technology in seven decades.
Siemens soon found the TiP TiG benefits on P91 - Duplex pipes.
The evolution of regular TIG is called TIP TIG:
Is your organization interested in a manual semi-automatic TIG weld process that will
applications provide welds 100 to 400% faster than traditional TIG?
Would you be interested in a no bells and whistles, all position weld process that will consistently
provide superior weld quality than regular TIG?
 Would you like to try a weld process that puts in less weld heat and therefore has potential to always produce superior mechanical and corrosion properties?
 Are you concerned about the new OSHA
requirements for weld fumes and would like a process
that does not require
exhaust equipment for most welds including stainless?
Click here for
info on TIP TIG Welding .
|The sad influence of salesmanship
on the global weld industry.
Welcome to the WORLD OF WELD REALITY:
For decades the global weld industry has relied on weld "sales advice
course as a result there has been extensive weld cost consequences.
A robot or any type of weld automation can only provide superior weld quality
than a human,
when the human who provides
the complete requirements of weld best practices and weld process controls.
Ed's Robot / Manual, MIG and Flux cored
Weld Practices and Weld Process Controls.
Will those poor welds at the Beijing
Birds Nest Olympic Stadium
mean, that one day the steel structure will turn into a spiders nest?
by Ed Craig.
Aug. 2. 2008.
five hundred million dollar, Beijing Olympic stadium was built on an earth quake fault. The steel stadium is wrapped
in a unique high strength, steel welded box cocoon that weighs approx. 45,000 tons.
While the world's focus was on the unique design my focus was on the sad weld practices used to build it.
At the end of July, two weeks before the 91,000 seat stadium was ready to host
the 2008 Olympics, I watched a Discovery Channel program about the stadium construction.
The steel Bird's Nest design is without question a wonder to behold,
however having a slight interest in fabrication and welding you know where my
focus was, and while I watched that TV show I did not like what I saw that was going on with the welds.
2009: Beijing Update: Check out what's happening to this
architect design wonder, nine months after Ed wrote his opinion on the poor welds
and construction at the Birds Nest stadium.
BELLS AND WHISTLES CANNOT COMPENSATE FOR LACK OF WELD PROCESS EXPERTISE?
Why do the majority of global weld shops rush to purchase the useless costly bells and whistles found in manual MIG pulsed equipment?
was my job as a Training and Weld Product Manager with companies such as Praxair, Airgas, AGA and Liquid
Carbonic to test MIG equipment and weld consumables available from around the globe. I did this for more than 30 years.
Today in 2012 you
can pay $3000 for a traditional MIG power source, or pay $12000 for a Lincoln pulsed MIG power source.
The weld reality is this.
With The MIG process control expertise available in this site's Weld Process Control Training Resources,
you will attain the same manual MIG and Flux Cored weld quality and productivity results from
both power sources on the majority of all steels and alloy steels weld applications.
WHY ARE COMPANIES WASTING MONEY ON UNNECESSARY CARBON STEEL METAL CORED
AND FLUX CORED WIRES
AND ON USELESS, COSTLY THREE COMPONENT MIG GAS MIXES?
It's a weld reality that in the global weld industry that we are in dire need of individuals who can live without the weld advice from a salesman, individuals that will take ownership of the equipment and processes on their weld shop floors, individuals that can make rational weld decisions based on technical
substance, individuals that are actually aware of the real costs of a weld.
weld shops will use Metal Cored or Flux Cored wires that can cost from $2
to $4/lb for steel welds made in the flat and horizontal weld positions, while the same weld quality and productivity could be attained from a MIG wire
that costs approx. $1/lb. Some salesman may have convinced their customers that the MIG process cannot achieve the desired weld quality or productivity results, however in a quick 10 minute demo I would prove them wrong on > 90% of applications.
are more MIG gas mixes available today than the cereals available in a super market. Global MIG gas confusion has been the norm for more than five
decades and gas companies thrive on the weld shop confusion which generates higher prices for their commodity products.
It's a sad
weld reality that the majority of the gas information found in weld
shops is based on engineering / management apathy, weld process ignorance and salesmanship.
If you use any three part gas mixes for carbon steels
and austenitic stainless applications, you are part of an industrial gas marketing
con game. For a few years I was on the AWS committee that wrote the USA. MIG Gas Specifications, and much of my efforts at the committee meetings went to keeping biased sales data out of the specification. (Many AWS spec committees are made up with individuals that typically make or sell the products being written about).
In the last three decades in my management roles at Airgas and AGA I developed four of the most practical MIG gas mixes sold in North
America. If you want the most affective, low cost MIG gas mixes and gas information without sales bias, visit the MIG Gas section at this site.
When will the manual - automated weld industry stop being a "PLAY AROUND" INDUSTRY?
If a machinist is not allowed to play around with their machine controls, why would any experienced weld manager, engineer or supervisor allow their weld personnel to play around with two simple MIG controls that in reality have hardly changed in the last six decades?
A QUESTION THAT COULD BE ASKED AT MANY PLANTS?
Why spend $150K on a robot cell and then let the weld personnel "PLAY AROUND" with the robot weld data.
When the robot MIG weld process utilized has been around for decades, and that process is attached to a costly robot, why would any experienced manufacturing manager or engineer accept poor robot weld quality and production?
A FUNDAMENTAL WELD REALITY: Since
the introduction of the MIG process, there has been little management
or engineering focus on "MIG Weld Process Control Expertise". The result is the majority
of global weld personnel "play around" with their simple MIG
or Flux Cored weld controls. There is an easy solution to lack of Process Control Expertise and lack of uniform Best Weld Practices. During the last three decades I developed the world's most simple, self teaching
weld process control training program called the Clock Method.
With my process control training resources, in a few hours your employees (without taking notes) will have all the process control
expertise and best practices necessary to instantly set correct, optimum weld parameters for any
MIG / Flux Cored steel applications.
attain optimum robot MIG weld quality and productivity or instantly deal with
robot weld issues requires MIG weld process control expertise. With the global
average robot MIG weld production efficiency range at only 40 to 60% of it's real
potential and robot weld rework usually in the range of 20 to 100%, many manufacturing
companies have a great opportunity for dramatic robot cost reductions and robot
weld quality improvements.
For a few years,
I was the North American Robot Weld Manager with ABB Robotics where I established the world's first Robot MIG weld Process Control Training Program. For the last decade as a consultant I have provided both manual and robot weld optimization to
companies in 13 different countries.
Before I optimize a companies robot welds, I start out by providing my Seven Steps to Robot MIG Process Controls Training Program to all the weld decision makers at the plant. I will not provide this type of training unless all the relevant management and engineers attend, (lack of management - engineering weld equipment - process ownership is a global problem). I developed the program so that anyone (no weld expertise required) could present it. Why not provide your employees
with my easy to use Robot or Manual, MIG or Flux Cored, weld Process Control" training
program, and also take a look at my Self Teaching MIG and flux cored weld
process control books and CDs.
a few hours of viewing this unique training program, that all the participants will have the
ability to instantly address their daily robot or manual MIG weld issues that impact the weld quality and productivity. Imagine no one in the plant "playing around with weld parameters" and imagine the plant management satisfaction in daily achieving consistent, optimum weld quality / productivity without weld rework.
WELD COSTS? You cannot control MIG - Flux Cored weld costs unless you fully understand the processes. A common weld produced is a MIG or flux cored 1/4 (6mm) fillet. In your organization you may not want to ask the engineering mgr - weld mgr or supervisor the real world weld costs associated with a fillet weld thats 10 inches long. If they attempt to answer, dont expect that answer straight away and if you ask three people, expect three different answers.
When you ask
a manager the cost of a MIG or flux cored weld,
the majority of managers typically will want to talk about the cost of the weld gas or the weld wire.
Many weld supervisors are happy as long as the welder's shield is down and weld smoke and spatter is being generated.
What management often are not aware is that welder can weld a vertical up flux cored 1/4 fillet at 6 lb/hr, or they can weld the same fillet
weld with the wire feed set to deliver >10 lb/hr. A MIG welder can weld a horizontal 1/4 fillet at 6 lb/hr or using my MIG process control data weld that fillet at 12 to 20 lb/hr.
The weld reality is few managers or supervisors understand the weld deposition rate potential of the weld process for the applications they daily weld, and less than five percent will have the process control knowledge and expertise necessary to
optimize their weld quality and control and understand their weld costs.
My unique, low cost weld process control training resources
enable the attainment of consistent, optimum MIG and flux cored weld quality and
productivity for the majority of weld applications and also these resources simplify all weld costs.
The shortage of MIG - Flux
Cored welders is simply a myth:
Why are managers and engineers concerned about the so called global shortage of MIG - TIG or flux cored weld personnel?
Welding Caterpillar parts or
welding ASME pipe 5G welds.
an instructor utilizes
my MIG - Flux Cored weld process control training methods,
you will find it should take approx.
to train a "none welder" with the capability to provide optimum
MIG and flux cored welds that
meet any global weld code / specification requirements.
you can also have them
attend a local weld training establishment and after six months
you may find they can stick weld and that they are also will be playing around with their MIG and flux cored weld controls.
As for the shortage of those highly skilled TIG pipe welds. If your organization used the Tip TiG process, they would find this process dramatically reduces the weld skills required for 5G pipe welds. With the right Tip TiG training, it should take a none welder about 5 - 10 days to pass any
5G ASME pipe test. The TiP TiG welds will be better quality than the TIG welds and they will be done 200 to 400% faster. Please remember this is not theory, I have already provided
this training to many companies and my MIG and flux cored training resources have been used in over 1000 companies in 13 countries.
If your organization is concerned about weld rework costs eating weld profits, or concerned with the qualification of welders to pass an all position pulsed MIG / flux
cored pipe or vee groove weld test, please note, you will dramatically improve the weld pass rate,
if before the welders strike an arc you provide the weld personnel with my four
hour classroom training program that actually shows them the correct techniques
and weld settings that enable weld process
"WELD PROCESS CONTROL EXPERTISE" IS THE
MISSING LINK FOR MOST GLOBAL
WELD COMPANIES THAT UTILIZE THE MIG - TIG and FLUX CORED WELD PROCESS.
API-ASME-AWS-NACE-ABS, all weld codes require optimum flux cored - MIG and TIG weld procedures for qualification,
yet every code weld that has failed or has serious defects are welds that were made with so
called, optimum, pre-qualified weld procedures.
Weld SKILLS have always been a small part of weld quality:
Apart from the welder's skills, an essential element to the success
of any weld project is the implementation of best weld practices and the weld personnel weld process control expertise. Its always interesting in any weld shop to watch the weld personnel response to the numerous variables that daily
influence the welds made on the shop floor or at the project.
"playing around" with their weld controls, how do your weld personnel
respond to the following? Welds that are undersize or welds with excess root gaps. Weld joint misalignment,
poor weld edge preparation, poor weld joint access, difficult out of position
welds, unacceptable surface conditions, and lets not forget the ever changing environmental issues, distortion,
spatter, undercut, porosity, cracks and lack of fusion?
A WELD REALITY: The solutions
to optimizing weld productivity and preventing weld defects and weld issues will be the one thing that most weld shops will never evaluate their employees or teach their
MANUAL - AUTOMATED ZERO WELD IS AN EASY GOAL FOR MOST WELD SHOPS:
While weld defects are influenced by many weld variables, all MIG - FCAW and TiP TiG welders should
have the ability to instantly change their practices and parameters to deal with the variables and therefore prevent weld defects from occurring.
Every weld shop
will derive tremendous quality - cost benefits from management, engineers, supervisors, technicians and employees
who have been trained to be aware of the root cause of MIG and flux cored weld
defects. As a weld shop decision make, if you want to create cost affective changes in the weld shop, you have two simple options;
 Get advice from a weld salesman.
 Use the unique manual / robot MIG and flux cored
weld process control training resources. available at this site.
|Many weld shop decision makers are often not aware that "Weld Skills" has nothing to do with "Weld Best Practices - Process Control Expertise"
Set that MIG pipe root or 16 gauge weld at
10'o'clock - 17 cups of coffee.
Ed's easy to remember Weld Process Control
"Clock Method". Copy
Right © Protected.
ED'S MANUAL - ROBOT, MIG & FLUX CORED WELD BEST PRACTICES
AND WELD PROCESS CONTROL TRAINING RESOURCES:
you are teaching yourself or providing weld process control training for
Ed's weld process controls and weld best practices
resources are the key to attaining optimum manual and robot MIG and flux cored welds.
The Book: "A Management & Engineers Guide To MIG
Productivity & Costs"
2. A unique robot
MIG training or self teaching resource.
Robot MIG Welds from Weld Process Controls".
unique MIG training or self teaching resource.
Manual MIG Weld Process Optimization from Weld
A unique flux cored training or self teaching resource.
"Optimum Manual and Automated Flux Cored Plate and
de Soldadura MIG Manual"
(MIG Made Simple.
Self teaching in Spanish)
Self Teaching MIG Book/ Video. (MIG
Made Simple in English).
Ed's Process Control Books and CD Training resources.
THEIR IS ALWAYS COST CONSEQUENCES FROM HAND'S OFF MANAGEMENT AND ENGINEERS:
The weld shop practices that for decades may have been influenced by inexperienced, hands off management - engineers and supervisors, has for many plants created an interesting weld shop culture that leads to extensive weld quality - cost consequences. For those with grey hair, you will have likely noted that in too many weld shops there is a glass wall that divides management and engineers from the weld shop floor. That dividing wall has often resulted in the "them versus us syndrome". In this unhealthy manufacturing environment, it's not uncommon to find the crew (welders) has taken over the ship, and the welders who do their own thing develop inflated egos in from the control they have in the weld shop. This old and very tired weld shop quagmire is ripe for the influence of a weld salesman and ripe for weld quality issues and weld costs which are out of control.
WELD PROCESS CONFUSION OPENS THE DOOR FOR THE SALESMAN: Weld shop confusion allows for the introduction and sales of weld equipment saturated with useless electronic bells and whistles and unecessary weld consumables. Lets face it, if that new MIG power source does not help the weld issues, the solution must be in that new three part gas mix they are going to demonstrate next week. I have been in many weld shops in which the weld distributor salesman spends more time on the weld shop floor than the weld shop manager.
WELD PROCESS CONFUSION ENABLES WELD COST SAVINGS: The good news, it's taken decades to create the cultural weld shop mess we too often see today, however with management driven change, there typically is great opportunity for most weld shops to attain dramatic weld quality improvements and cost savings.
2012 AND FORTUNE 500 APATHY: Most of you are aware of the lack of weld management in the Auto industry and It should be no surprise to find that many major USA fortune 500 companies have too many facilities that are stuck in a 1960 - 1970 weld manufacturing time warp. These corportaions typically rose to greatness as a result of research, innovation and strong management leadership.
In the last decade, as I visited many of these companies reference their weld issues, I frequently witnessed minimal focus on engineering R & D, and that the manufacturing practices - processes and procedures utilized were typically established in the 1960 - 70s. The reality was while the past practices built these corporations, too many managers and engineers are today ensuring they remain entrenced in that past.
Manufacturing management and engineering apathy is rarely discussed in
yet it's one of the prime reasons we no longer produce good paying jobs
So the next time you see a major USA chemical company order a 30 foot diameter, 5/8 wall stainless tank
and the sad weld specification calls for the SMAW (stick) process, smile and be paitent with their engineers because thats the way the tank was first built in 1967. And the reality is, if the management and engineers wanted to improve the weld quality and examine a more cost effective approach to build that tank, they would have to take ownership of the project and without listening to a salesman go out and actually learn something new about welding.
WELD QUALITY AND COST CONSEQUENCES FROM:
Lack of Management Weld Process Ownership.
Design & Engineering Weld Apathy.
and Supervisors reliance on sales advice.
Lack of global Best Weld Practices.
Lack of weld Process Controls.
Weld Cost Ignorance.
Always high risk and liability consequences.
every four robot MIG welds found in the auto / truck
industry don't be surprised to
find that typically
two welds will have lack
of weld fusion or excess porosity.
weld reality of the the majority of robot MIG welds that join global cars and truck parts, is the
average weld size is approx. 4 mm, while the average gage part thickness welded is less than
3 mm. Thanks to the general lack of best weld practices and lack of MIG process
control expertise in these industries, it's too frequently the "over
weld" rather than the robot or manual MIG - FCAW weld integrity that holds together
those >$25,000 vehicles.
Robot Weld Process Control Training resources are
simple to use. These resources will ensure
the personnel in your
always attain the full weld
quality - productivity
the robot - MIG equipment selected. Click here for info.
As above, when I have to use with this Miller power source useless Bells and Whistles to set MIG
I know that this robot weld shop has been advised by a salesman.
As Ed found out at a the above tier one auto supplier in Spain, Miller
seems to be
an on going serious weld problem
it was having with it's Axcess MIG equipment.
Check the MIG equipment selection for more info.
For many companies
would be a first.
Where are the qualified
global weld managers?
LET THE WEB TELL YOU HOW IMPORTANT THE "WELD MANAGERS" JOB IS:
the world's largest career web site "monster.com" and type in the key
words "WELD QUALITY MANAGER"
and monster will typically provide many jobs in the USA. Now try the key words, "WELD
MANAGER" and typically less than three jobs will be evident.
Its always been more important to prevent weld defects rather than find them and a good weld manager would know how to achieve this. The problem in the global weld industry is no more tha 10 percent of this industry has managers that are Weld Process Control experts. If weld engineers at the major universities are not getting the process control education they need, what can you expect from the average weld shop manager or supervisor?
In the majority of global MIG
weld shops, few managers have
established best MIG and flux cored weld practices, few managers have implemented
effective weld process controls. Few weld managers are "hands on" and few managers have the ability to quickly get to
the root causes of their daily welding
issues or weld costs.
Corporations in industrlal nations need
to be aware that optimum MIG - TIG - FCA weld quality and productivity is easy to attain in third world weld shops that may pay less than $2 /hr for it's weld labor costs. For those of you having an acid attack, try not to blame the messanger, put your energy into working out the the cost of a simple 3/16 or 1/4 (4.8 - 6.4 mm) MIG or FCA fillet weld one meter in length. (my self teaching process controls simplifies this requirement while showing you how to attain the highest weld quality at the lowest possible weld costs).
OF COURSE THERE ARE DRAMATIC MANUAL - ROBOT
WELD COST CONSEQUENCES FROM
THE GLOBAL LACK OF MIG MANAGEMENT
WELD PROCESS OWNERSHIP.
more than two decades, in global manufacturing facilities, over
90% of MIG welding robots have been set up by inexperienced robot companies and integrators and owned and controlled by inexperienced plant technicians.
majority of the technicians responsible for the weld data utilized
in the robots never received MIG Weld Process Control Training. Combine the global lack of
MIG weld process control expertise with the too frequent apathetic engineering /
manufacturing standards that result in the common, unacceptable, weld part dimensional
tolerances, then mix in poor weld fixture design and poor robot cell / fixture maintenance and what a global, daily waste we have in the purchase of that costly robot weld automation.
NEVER ASK A DESIGNER OF AUTO - TRUCK WELDED COMPONENTS, A SIMPLE WELD QUESTION:
DESIGNERS DON'T CONSISDER THIS STUFF:
From car seats to car frames, thin wall tubes are great for increased strength and stiffness, however
tubular components offer unique robot MIG weld - energy concerns. In a "J"
groove tube joint associated with welding round to flat gage parts as indicated on the right, the required increased
weld mass necessary for the "J" fill, dissipates some of the energy that would typically be
applied to attain side wall weld fusion.
FROM WELDING THIN GUAGE PARTS TO WELDING
7 mm FILLET WELDS, FEW WELD SHOPS UNDERSTAND THAT TOO OFTEN THE "MIG PROCESS DELIVERS A POOR RATIO BETWEEN
THE WELD ENERGY PRODUCED AND
THE WELD MASS AND WELD SPEED DELIVERED".
Combine the poor fusion with the frequent short
cycle weld times that often result in small weld lengths and the rapid freeze, low energy welds will
often end up with welds that on the surface look sound, however as this 1.4
mm tube to brkt weld macro reveals, lack of robot MIG weld fusion will be common. J grooves welds typically require > 200% more weld necessary for the part thickness welded. An oversize MIG weld adds to the excess part heat in the welds HAZ, (an issue with reverse polarity weld processes). The high part heat will weaken the tube parts.
weld fusion - porosity on cold rolled components will also be influenced by lubricating oils from the
manufacturing process. Also on tube welds its difficult to control
the robot TCP and attain consistent robot weld speeds from the robot's multi-axis
rotation movement. The quality and consistency of the robot programming, the global lack of weld process control expertise with robot operators, the parameter influence
of MIG wire stick variations out and wire helix issues can influence the weld quality attained on small round welds.
As mentioned small tubular welds are often over sized welds and these REVERSE POLARITY welds will rapidly build up weld heat in a small localized area. On thin
gage HSS tube steels, the excess weld heat in the HAZ has to be a concern especially when additional weld passes are delivered from weld rework
which is typical with auto / truck robot applications. To
retain some of the High Strength Steel (HSS) structural integrity in the weld's heat affected zones, it's critical
in the robot welding of these high strength components, to ensure that correct weld sizes are applied and manual
MIG weld rework is minimized. Also whats the sense of providing welds if they dont consistently provide weld fusion.
The HSS small tube robot weld application is one that management is advised to keep their millwrights,
electricians and other inexperienced maintenance personnel away from. These robot welded parts don't need inexperienced maintainence personnel "playing
around" with the robot weld data making "unqualified weld changes. The weld solutions to
all of these issues are addressed
in my robot weld process control training
CONCLUSION: It's fine for designers and engineers to talk about the reduced weight benefits
of high strength steels, however if you destroy the properties of those steels
with unnecessary weld heat, if you weld parts in which manuafacturing has lost dimensional control of the parts and weld gaps, or you create difficult weld joints, you will produce welds with questionable and unnaceptable quality. If this is the case and lawers out there take note, what's the real
benefit of the high strength tubular steels or any car - truck steels when it come to vehical collisions?
Successfully welding auto - truck components and avoiding future weld failure liability consequences, will come
from designers, engineers, management and robot weld personnel who understand the robots, the weld processes and consumables used. All engineers and robot weld decision makers working with robot welded part should be aware of the fundamentals in my Best Weld Practices and Robot Weld Process
Controls Training Resource.
ROBOTS, WELD COSTS AND POOR
MIG WELDING PRODUCTION EFFICIENCY:
i have been in hundreds of plants in 13 countries that use MIG welding robots and in the majority, it's typical to find the plants will use three
robots to do the work that two could do. The managers and engineers in these plants will not be aware of this costly fact as they do not understand the process requirements necessary to attain optimum robot weld production without weld rework.
For more than two decades in the auto / truck industry,
the typical, high volume, robot weld down time
per-8 hr/shift has been a ridiculous 60 to 90 minutes,
which according to Detroit auto industry sources, can result in an approx. cost
of $2000 - $2500 per-hour.
my numerous visits to Detroit plants that were having robot
I found few managers or engineers understood the root cause of their robot weld issues and and even fewer wanted to get involved.
2013. The average global, robot MIG weld
production efficiency range is 40 to 65% and the
average robot weld rework range is 20 to 100%.
The last thing a weld shop needs is to ask weld QA personnel who typically have no weld process control expertise a question on weld process quality - productivity issues. QA personnel who are process control experienced are typically wasted in the majority of weld shops as the management and engineers direct them to react after the welds are complete.
For decades too
many global manufacturing companies have placed their weld quality labor resources and focus on "finding
rather than on providing their employees (including QA personnel) with highly cost effective
weld process control training programs, that would "enable weld defect prevention".
GLOBAL WELD QUALITY DEMISE:
never been a bigger demand for QA managers and weld inspectors,
yet the demand for weld managers,
engineers, supervisors and
technicians with Weld Best Practice Capability and Weld
Process Control Expertise
has always been almost none existent.
 IS YOUR ORGANIZATION CLOSE TO MAKING A LARGE WELD AUTOMATION OR WELD
EQUIPMENT INVESTMENT AND YOU WOULD LIKE TO KNOW HOW TO ATTAIN OPTIMUM WELD QUALITY AND PRODUCTIVITY WITHOUT THE PURCHASE OF COSTLY, USELESS BELLS AND WHISTLES?
Do you have weld design concerns or looking for design tips that
can enhance weld optimization from your weld automation?
 ARE YOU SIMPLY LOOKING TO RESOLVE
WELD PROBLEMS OR LOOKING FOR THE MOST COST EFFECTIVE EFFECTIVE WELD PROCESS DATA AND PROCEDURES?
 Perhaps you have a MIG / Flux Cored welder shortage at your locations and would like to provide the world's most effective robot - manual MIG process control training programs. With a few hours process training your employees will exceed your expectations.
AT THIS SITE YOU WILL FIND THE WORLD'S MOST EFFECTIVE MIG AND FLUX CORED PROCESS CONTROL TRAINING RESOURCES.
FOR A LOW COST, FAST SOLUTION TO YOUR ROBOT / MANUAL WELDING ISSUES, CONTACT ED.
Ed has resolved weld issues for hundreds of companies and many
of the weld issues were resolved with a phone call or by E-mail .
For info E-mail.
firstname.lastname@example.org, call 828 337 2695
WHEN WELD MANAGEMENT DOES NOT RECOGNIZES THE IMPORTANCE
OF WELD PROCESS CONTROL EXPERTISE, THEIR WELD ACCEPTANCE STANDARDS
WILL BE LOW, THEY
WILL KEEP HAVING
MEETINGS ASKING THE SAME OLD QUESTIONS AND THE WELD SALES REP WILL BE A FREQUENT VISITOR..
a tool maker, machinist, mechanic or electrician "plays around" with their equipment
or ask a sales rep for advice?
Be a professional like my grandson Riley. Train your weld
they don't have to Ask
a Lincoln Rep how to weld a part someone likely welded 50 years ago.
WELD MANAGERS OR FIREMEN? In
a weld manufacturing facility in which the MIG or flux cored weld quality and
productivity are not optimized, it's not uncommon to find engineers, supervisors, technicians and management
in the constant fireman mode, daily
trying to quench the weld production / quality fires.
 In the fireman's plant we often find ISO deeply embedded,
KAIZEN is a second language, BLACK BELTS are in abundance while many of the common manufacturing processes like paint, resistance and MIG welding are out of control.
 In the fireman's plant you will find the management and engineers are incapable of establishing uniform Best Weld Practices and Robot - Manual Weld Process Controls.
In the fireman's plant you will not find anyone that within five minutes can tell
you the cost of a common weld
 In the fireman]s plant you will not find managers or engineers that have taken ownership of the manufacturing
processes that create their profits.
Many of you reading this have been in the weld industry for many years, yet how
many of you have
worked with managers or engineers who have established Best MIG Weld Practices
or implemented effective Weld Process Controls?
How many weld decision makers have you met that
can look at a weld and instantly know the optimum consumables utilized, the optimum weld data used, the weld deposition rate attained and the robot weld speed potential for those welds?
highly skilled weld individuals with 20 plus years MIG weld experience are aware
of the weld process solutions to their common daily robot MIG weld process issues?
WHERE ARE THOSE EFFECTIVE WELD PROCEDURES? Weld procedures are not weld process controls. In north America, we loose billions
of dollars each year on weld rejects and unnecessary weld rework, and the majority of those welded
parts had so called pre qualified weld procedures. We should all recogognize that welding skills are only a small part of the requirements for optimum welds. The reason for most welds issues is simple. The individuals setting and controlling the procedures and welds lack the weld process best practices expertise. Apart from best practices and process controls, the manual or robot weld procedure data should also compensate for the variables that will daily influence the intended weld applications.
For decades I walked through weld shops in 13 countries, searching to find a weld decision maker who;
did not need the advice of a weld salesman,
[b] understood the importance of weld best practices - process controls.
[c] were aware of their real weld costs.
It was not a fruitfull saerch.
With my roles as
a weld training manger and weld product marketing manager for Praxair, Airgas, AGA, and Liquid Carbonic,
I have delt with more than 1000 salesmen, which I believe allows me to have an opion on weld reps and and their qualifications.
to decades of global MIG weld industry reliance on sales advice, three of the
largest growth and most profitable weld products sold in industrial nations for welding carbon steels are,
 costly, unnecessary pulsed MIG equipment,
 costly, unnecessary metal cored wires,
 costly, and unnecessary three
part gas mixes.
As its been for three decades, and today in 2011, if the above three products were no longer available to the weld shops that
weld mostly carbon steels, low alloy steels and stainless, there would be no impact
on the global weld industry's weld quality and productivity.
There are many weld decision makers who need to cut their Umbilical Cord which is attached to their local weld sales rep:
MIG or flux cored weld advice is needed, many weld shops with weld personnel who
have been in the business for decades will not think twice about asking a weld equipment rep or salesman who's education back ground is a degree in
English or Fine Arts.
The sales reps and their biased advice are usually ready to recommend another new, useless three
/ four part gas mix, or their latest $11,999.99 pulsed MIG power source with it's programmable
magic wave forms, sensitive circuit boards and short life span. If you want evidence of the MIG weld equipment and confusion, take a
look around your shop:
 How many different power sources, welding wires and gas
can you count, and how many have you tried in the last few years?
 How many welders in your shop daily play around with their weld controls?
 Why do you have spatter issues on your parts?
 Why do welds on the same parts look so different?
 Why are welds being rejected or require rework?
HOW CAN MANAGERS MAXIMIZE WELD PROFITS, IF THE MANAGERS DON'T FULLY UNDERSTAND WELD COSTS? Understanding weld costs: Few weld shops have individuals that can
work out the cost of a common
3/16 or 1/4 ( 5 - 6 mm) fillet weld. When asked about
their weld costs, the
majority of global weld shop managers and supervisors will
want to discuss the cost of the weld wires or weld gas mixes. Weld Deposition Rate Potential
Per-Welds are words rarely used. Weld shops can not control weld costs till weld decision makers understand weld costs.
If it takes you or anyone else in your organization more than 5 minutes to work out the cost of any weld, you lack
weld process control expertise. The solution is simple, spend a few hours with my low cost weld process control resources and you will have complete control of any weld cost.
|WHEN MANAGERS LACK WELD PROCESS - EQUIPMENT OWNERSHIP AND WELD ISSUES OCCUR. THE MANAGERS TOO OFTEN FOCUS ON THE WELD PERSONNEL RATHER THAN ON THE REAL ROOT CAUSES.
|If optimum welds can be made by stupid machines, when best weld practices and process control expertise is applied.
MIG process is over fifty years old, yet I wonder how
many weld decision
makers in a weld shop would be able
to answer the following fundamental weld
LIKE MOST YOUR FOCUS IN ON THE WELDERS SKILLS. HOW IMPORTANT
ARE THE FOLLOWING FUNDAMENTAL WELD PROCESS
CONTROL QUESTIONS TO YOUR ORGANIZATION?
your Weld Process Knowledge with these fundamental weld questions. If
it takes you more than 15 minutes to provide the correct answers to the following
questions you are not in control of the world's most common
weld equipment and consumables.
What is the MIG wire feed setting in inch/min (m/min) in which an 0.045 (1.2mm) wire
using argon - 20% CO2
goes into Spray Transfer?
 What weld parameter changes will be necessary
if you change your MIG gas from argon 20% CO2 to argon 10% CO2?
Using an 0.035 (0.9mm) wire, what wire feed setting in inch/min (m/min), does short
circuit transfer change
into spray transfer when using argon
- 20% CO2?
 Why is the common argon - 25% CO2 mix the worst possible weld gas for companies who
weld parts thicker than 3mm?
 You are using a robot to weld a common 3/16 (5mm) carbon steel,
horizontal fillet weld.
You use an 0.045 (1.2 mm) wire and
argon - 10%CO2. To meet your weld production needs you need
to attain a weld travel speed of > 40 ipm. Provide the
Wire Feed Speed____ inch/min. Required Amps ____ Volts___.
Your robot cell goes through six contact tips each day. The robot welds 1/4 (6mm)
using an 0.045 MIG wire and
argon - 10% CO2. The wire feed data is
280 inch/min (7 m/min) with 25 weld volts.
Why are you having daily contact tip issues?
 Using a mechanized weld carriage or a robot to
weld a 1/4 (6mm), Horizontal Fillet Weld with an 0.045 (1.2mm)
E71T-1 flux cored
wire and argon 20% CO2. Provide the Wire Feed Rate____Weld Travel Rate____Voltage____.
 What is the MIG weld cost for an application which has
6 feet of weld (1.5 meters) of 1/4 (6 mm) horizontal fillet welds on each part. To weld the part you are
using the common 0.045 (1.2mm) MIG wire which cost $1 /lb. Your argon - CO2 gas mix cost is $40 per-cyl.
The wire feed rate used is 420 inch/min with 30 volts. Your welders have an
overhead rate of
$60 / hr. The MIG welders average arc on time is 30 minutes per-hr.
Welding 1/4 (6 mm) structural carbon steels with flux cored. The weld position is vertical up. The flux cored wire is
E71T-1, 0.045 (1.2mm). Gas argon - 25% CO2. Without asking the sales rep, provide the optimum wire feed, amps and voltage.
You have an automated weld unit that runs on a track, (or using a robot). Your MIG spray transfer weld is oversize.
Without touching the wire feed rate, you increase the weld travel rate by 20%.
What will you have to do to the weld voltage and explain why?
 You are using Helium Tri Mixes for MIG welding thin gage <3 mm stainless. Why is this gas mix the wrong choice?
 You are using MIG Spray or Pulsed MIG and you have weld spatter, to get rid of the weld spatter what do you adjust and why?
 You are welding thin gage with short circuit and you have weld spatter, to get rid of the spatter what do you adjust and why?
 At the end of your robot welds there is a large glob on the end of the weld wire. The glob is causing robot arc start issues. How do you get rid of the glob?
Note: Ask your self, are the above weld process control questions relevant to your weld personnel and important to the reputation and profitability of your organization, if so when are you going to do something about it? If you had
difficulty with the fundamental MIG and Flux Cored weld process questions, don't feel frustrated,
after all, for more than six decades the weld industry and most weld educators have
placed minimal focus on this subject.
Ed's flux cored process control Weld Test,
 Ed's MIG process control MIG Welding Test.
You may know a MANAGER, ENGINEER OR SUPERVISOR LIKE THIS:
is the manager or engineer who daily has his head buried in the sand. This is the man who should be running the local doughnut shop, the manager who believes that
MIG welding is a "play around with controls trade". This guy will be the best friend with the local sales or Lincoln rep. This is the manager who believes that weld productivity
is measured by how long the welder's hood is down and his company's daily weld quality
and productivity depends on the temperament and artistic skill level of each welder.
you ask this manager about his "weld costs" he typically wants to discuss the
cost of the weld wires and gas mixes.
 When this manager has weld issues, he will
not think twice about calling Lincoln - Miller - ESAB or asking the local weld sales
rep for advice.
 This is the manager who has no problem spending unnecessary
dollars on the latest three part gas mixes or on costly useless pulsed MIG equipment loaded with
ineffective electronic bells and whistles.
will be the manager who daily accepts inconsistent, manual, weld quality and unacceptable
productivity as the norm, and his expectations from his experienced, skilled workers and costly robots is not
Or you may know a MANAGER, ENGINEER OR SUPERVISOR LIKE THIS:
These are the weld decision makers who are tired with the futile finger pointing, and the never changing weld shop issues. These guys will be fed up with the time wasting useless weld meetings in which BS is the norm and weld solutions are rare.
 These individuals will be frustrated
that their so called experienced weld personnel have to "play around" with the
decades old MIG and Flux Cored weld processes.
 These will be the guys who no longer want to read weekly
reports full of excuses for the inconsistent, robot or manual, MIG flux cored
weld quality and productivity.
 These are the managers that know that optimum MIG - FCA weld process
comes from the plants that will have the ability to establish Best Weld Practices and Weld Process Controls.
These managers will
know that to achieve this their employees need more than skills they need special process control training. Click for Weld Best Practice - Process Control Resources.
YOU SHOULD NOT BE IN THIS INDUSTRY IF YOU DON'T
HAVE A SENSE OF HUMOR AND VERY THICK SKIN:
hope like myself you have thick skin, are not upset with the messenger and focused on the message. I hope this site can be a catalyst for progressive, cost effective weld
for your organization. I also hope the www.weldreality.com information encourages managers and engineers
and supervisors towards Weld Process Ownership and that this site reduces some of the common MIG / flux cored
weld process issues, myths, confusion and sales reliance that's common in most global
MIG weld shops.
EXON - HALIBURTON - GM
- ROLLS ROYCE - IMPERIAL OIL - FORD - CHRYSLER HARLEY - DANA - MAGNA - TENNECO - VOLVO - TOYOTA
- HONDA - IMPERIAL OIL - COMBUSTION ENGINEERING
- GENERAL ELECTRIC - CATERPILLAR - JOHN DEERE - MERCEDES - DOW CHEMICAL - BABCOCK - ABB
- GENERAL DYNAMICS -
VW - TEXTRON - INGERSOLL
RAND - ESSO are just a few companies that utilized Ed's robot / manual process
control services, expertise or training resources.
Ed provides weld process quality / productivity solutions for a reasonable fee.
Contact Ed. E-mail. email@example.com.
Ed's Robot and Manual MIG and Flux Cored Weld Process Control Training power point presentation should be provided to all personnel involved in the weld process and involved in weld process decisions and that includes management, engineers, supervisors, technicians QA personnel and all weld personnel.
When everyone in the weld department walks the same welding path and training is provided, Uniform Best Weld Practices and Weld Process Controls can be implemented and the following should result.
 All robot or manual pre-qualified weld procedures will provide data that deal with all the
real world part and weld variables that influence the weld quality and productivity.
 Shop floor Manufacturing and Weld Instructions
will be logical, optimum, complete, effective and highly visible.
 Weld personnel will be aware of how to instantly set optimum weld data for any weld, any alloy, any wire, any weld issue without "playing around" with weld parameters.
 Weld clean up and weld rework will become miniscule.
 Managers and supervisors will know the real cost of the welds produced.
Supervisors, engineers and technicians will always be aware of the weld production potential in terms of weld deposition rates and weld travel speeds per application.
all of Ed's MIG and Flux Cored self teaching and Weld Process Control Training programs
NO ONE uses more flux cored wires than a ship yard or a facility making oil - gas platforms.
 NO ONE has more weld defects than these facilities.
 NO ONE has greater weld repair costs than these facilities.
Yet the sad weld reality is this. If you want to find lack of management and engineering weld "process ownership", the first place you visit is the above facilities and the next place is an automotive - truck plant. The good news is for those employed today in these industries, there is the greatest opportnity for someone to be a hero by producing tremendous weld cost savings.
the weld cost section, take a look at the multi-million dollar cost savings, one
ship yard attained
using my one day flux cored process control weld training program.
As a weld process control expert, you should have the ability to instantly master any manual or automated weld equipment - consumables utilized, and without playing around with the controls, attain both optimum weld performance and productivity with all welds.
As a weld process control expert you know it's your responsibility to ensure the correct process control training is provided.
Imagine a weld shop in which all the weld personnel
are aware of the root causes of the manual / robot MIG and flux cored weld problems, and these employees have the
ability to provide instant, logical solutions to their weld issues, without playing around with the weld controls.
Imagine a weld shop in which all weld personnel understand the relationship between
the wire type, weld gas, wire diameter, weld transfer mode, part thickness and the weld deposition
rates and weld travel speeds required and the welders are also using the correct weld practices and techniques for the process and consumables utilized.
It's always "rare pleasure" to watch the weld personnel I have trained over the years when they act in a professional manner and
instantly set optimum manual or robot weld parameters for their application.
Ed's MIG - TIG - Flux Cored Process Control Workshops:
participants from six countries including Australia,
Canada, attended one of Ed's work shops called "Seven Steps to Robot - Manual MIG Weld Process Controls".
|For both Ford and Dana engineers, it was a rare
opportunity for their engineers to witness consistent optimum robot weld quality.
Ed's Robot Process MIG Weld Control training CD
dramatically improved the
weld quality and productivity
on Ford F-150, the
world's biggest selling truck.
From Dana Weld Eng To
2007: Ed. I wanted to send update about the E-Town Dana plant that you visited a few
years ago: As you know on your first visit to this plant, our robot lines were
producing less than 40 truck
frames (Ford F-150) per-hour and the majority of the MIG welded frames required
extensive weld rework. Thanks to your MIG Weld Process Control Training and
your consumable / parameter changes and recommendations, the results from our employees are today
staggering. Yesterday this plant hit very close to a record of 76
frames per hour. We now daily attain our average goal of more than 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
thanks from! R Good. Dana Weld Eng and thanks from a grateful Dana
from Ed: It's great to hear a robot welding success story like this, especially
as there was initial management - engineering apathy and resistance to the changes I recommended. The Dana / Ford truck frame weld quality and productivity results were eventually attained
with fundamental weld process and consumable logic. The robot process control
data and advice I provided this company is available in my books and in my Robot
/ Manual Weld Process Control Training CD programs located here.
Welding conventional carbon and alloy steels? I
visit the pulsed MIG section to
view why you should
not waste $6000
- $120000 on that pulsed MIG power source.
MIG WELD GAS CONFUSION:
are more than 60 MIG gas mixes available for your MIG
applications when no more than 4 mixes are typically required. In
general, the common global MIG gas confusion is simply a
reflection of the
global weld industry lack of MIG process expertise.
developed the MIG gas mixes that provide real world weld benefits.
Note: Working in management with AGA,
Airgas and Liquid
Ed developed and introduced four of the
top selling MIG gas mixes used in North
A message to automotive management - engineers.
AMERICA'S SELF INDUCED RECESSION: As
the automotive executives lined up in like poor sheep to borrow billions from American
taxpayers, any logical individual would ask. Why does the auto industry, which
has one of the highest ratio of engineers to workers, annually create billions of dollars in rework, rejects, recalls, warranty and productivity issues?
the same industry millions of dollars are lost daily from robot
weld rejects, weld rework and poor robot weld production efficiency. In this bottomless pit cash quagmire industry, the
majority of plant managers and engineers seem to lack the ability to establish Uniform Best Weld Practices
and apply logical cost effective Weld Process Controls to their plant's critical manufacturing processes. Something for corporate executives, managers and engineers to think about.
EITHER NO WELD
JOB DESCRIPTION OR THE WRONG DESCRIPTION?
quality and productivity issues will always be more numerous in weld shops in
which confused managers, surround themselves with confused supervisors, who are
surrounded by confused engineers, who are surrounded by confused employees who
get no assistance from their none existing or confused job descriptions: A well run weld shop starts out with all weld personnel having job descriptions that clearly identify their required expertise and responsibility and accountability for the weld quality - productivity attained.
FOR DECADES, MANY AUTO / TRUCK PLANT MANAGERS HAVE ALLOWED MAINTENANCE
MILLWRIGHTS AND ELECTRICIANS AND OTHER UNQUALIFIED PLANT PERSONNEL TO DAILY ADJUST THE
SO CALLED "PRE-QUALIFIED WELD PARAMETERS" ON THEIR ROBOT MIG WELDS.
every time I walk past the robot cells, some millwright or electrician from the
maintenance department is playing around with the robot weld data. For
heavens sake our experienced welders play around with MIG controls,
do you seriously believe those guys in the maintenance department
with there 150 - 200 amp Miller MIG machine, have the MIG weld process control expertise
necessary to optimize robot MIG welds? Also in case we ever get sued, perhaps you can tell me why are these unqualified guys are changing the so called, "pre-qualified
weld data" without engineering approval and new weld qualification?
If you are relatively new to the auto - truck industry take note that few Global MIG welding robots qre well managed.
"The majority of the technicians and engineers who run robots are simply
operating equipment and a process. You will find that less than 10% of the personnel that daily make adjustments to the robot programs are in full control of the robots, and less than 2% will have full control of the welding process utilized.
The above statement was from
a weld report I provided to the Ford (Detroit) Frame plant management in the 1980s. It was futile message at that time as the managers and engineers running the plant simply did not understand the concept of weld process ownership and they also lacked the interest, knowledge or ability to grasp the root cause of their daily robot weld issues.
few of the work shop participants at Ed's 2007,
Seven Steps for Robot Weld Process
Wolf Robotics. Colorado.
|You can purchase my Seven Step Robot program for around $400. Any questions
- FORD - HARLEY - DANA - MAGNA - TENNECO - VOLVO - TOYOTA
- HONDA - IMPERIAL OIL -
- CATERPILLAR - JOHN DEERE - MERCEDES - DOW CHEMICAL - ESSO BABCOCK -
ABB - GENERAL
GENERAL ELECTRIC - VW - TEXTRON - INGERSOLL
The above, are just a few companies
that utilized my Weld training resources.
What's in Home Page Section Two ?
 View the best inconel, stainless, pulsed MIG clad welds that have ever been made in North America.
Why are too many companies that do code quality welds stuck
in a 1960s weld time warp?
Why companies should not use self shielded flux cored wires, especially when they want to attain quality welds and good mechanicals.
When the weld equipment and processes are not optimized you would think someone in management wants to generate change.
If you have any sense you don't MIG weld like most Japanese companies.
 What makes a dream weld team?
 At least these Japanese car parts managers were interested in the robot weld quality - productivity potential.
 How Chrysler lost over 20 million dollars on bad welds on one easy to weld part.
 Why you might as well take the millions of dollars used annualy for welder training in the auto - truck industry, and throw it out of the window.
Continue Home Page Sect 2.
Or perhaps you are interested in seeing how easy it is to save millions of dollars with large weld fabrication projects take a look at the following;
HOW AKER KAVERNER SHIP YARD SAVED MILLIONS FROM WELD QUALITY - PRODUCTIVITY IMPROVEMENTS:
HOW IMPERIAL OIL SAVED MILLIONS FROM INCREASED PIPE WELD PRODUCTIVITY. Click here.
Please don't leave this site without checking all the MIG- Flux Cored - TIG best
practices and process control information.