The Flux Cored Process
Control Training CD:

Weld Process Controls for gas shielded flux cored
wires welding pipe and plate welds"

Produced by Ed Craig.
A power point training program available on a CD:


E-mail Feb 2007

Ed. I have read book about flux cored weld parameters and reviewed the CD flux cored training power point slides many times. The methods in which you address the root cause of the common flux cored weld issues are unique and make complete sense. Your program simplifies the requirements for all position structural steels, plate and pipe welds, and those difficult ceramic backed vee groove applications are now one less thing to worry about. I have learned many things that give me a better understanding of how to quickly correct the weld issues and set / fine tune the weld equipment for the many variables that occur.

By the way Ed you are correct most of these welders I work with know little about how to set the weld machine correctly. Many of these guys have great skills, however because of their improper parameter selection and techniques, they daily create lack of fusion, porosity and slag issues. What's ironic is after they repair the welds, they then create more of the same weld problems. Thanks again for the flux cored book and CD.

Gary

HOW WELL DO YOU THINK YOU KNOW
THE FLUX CORED PROCESS . WHY NOT TAKE TEST?

All Position Fillets and Vee Grooves with Pipe and Plate Welds.
E71T-1 - E70T-1 Gas Shielded Flux Cored Wires.

2008: One of my prime welding goals during the last forty years has been "Weld Process Control Simplification". During the last three decades, the flux cored process acceptance has been painfully slow. The slow process evolution was simply due to the general global weld process confusion. It was a simple fact, that when the E71T-1 product was presented to many weld shops that few weld personnel could set the required optimum weld parameters.

With this flux cored CD, I present a unique, simple solution to flux cored weld parameter optimization. With a few hours everyone who views the program will understand where to set the optimum, all position flux cored weld parameters, (including MIG pipe root parameters) using either standard or digital feeders, Inverters and traditional CV MIG equipment.

You do not need weld process expertise to present this as a training program, simply point and click and you will find the program will take you on a path to the establishment of Best Flux Cored Weld Practices and Weld Process Controls.

THE VALUE OF FLUX CORED WELD
PROCESS CONTROL KNOWLEDGE:

In 2007, Ed presented this flux cored program to a North East, US ship yard that was loosing millions each year on flux cored weld rework. This part of the program requires only 4 hours per-employee. Within 4 months they had reduced that rework cost by approx. 60%. When you can instantly address the root cause of your daily flux cored weld issues and you have the process knowledge to prevent those issues, you know the value that brings to you and your welding company.

 

This flux cored process control program provide the resolutions to;

[] lack of weld fusion,
[] weld and HAZ cracks,
[] excess weld slag entrapment,
[] excess weld porosity.
[] excess open root gaps.
[] excess root gaps steel or ceramic backing.
[] maximizing weld productivity.

If your organization uses the E70T-1 / E71T-1 wires, and welds fillet welds, open root pipe joints and pressure vessels, all position structural welds, plate vee groove weld joints, or welding vee grooves with "ceramic" or steel backing, this training program enables instant, optimum flux cored weld solutions to all your gas shielded flux cored weld quality and productivity issues.

 

[] Imagine a weld shop in which every welder and supervisor knows how to set optimum, all position flux cored weld data, (no playing around with the parameters) on any carbon steels and stainless, all position applications.

[] Imagine a weld shop in which the weld personnel have the ability to instantly set optimum MIG weld parameters for those short circuit, STT or RMD pipe root passes.

[] Imagine a shop in which welders and supervisors understand the unique differences between all position welding on a pipe vee grooves with a 3 mm open root and and welding a plate vee groove with steel or ceramic backing with root openings from 8 to 25 mm.

[] Image a shop in which welders and supervisors are aware of the correct skills and technique differences between stick welding, GMAW and flux cored welding.

[] Imagine a shop in which managers, supervisors and welders understand the application and welds most prone to weld defects and provide the correct parameter and technique solutions to reduce the weld defect potential.

[] Imagine a weld shop in which a welder picks up a Bug-O (automatic weld carriage) and the welder actually instantly selects the optimum flux cored weld parameters, weld weave and weld speeds for that 6 mm vert up fillet weld.

Note: With the many variables found in thick plate and pipe construction, the flux cored requirements "for optimum root, fill and cap weld passes" will rarely come from the weld procedure tucked away in the quality managers office.

[] Imagine a shop in which welders, supervisors and managers understand the unique all position flux cored weld parameter and technique requirements for vee groove welds with ceramic or steel backing.

 

THE IMPORTANCE OF GAS SHIELDED FLUX
CORED WELD PROCESS EXPERTISE:


[] The fact that many of your weld personnel have to "play around" with the flux cored weld data should tell you something.

[] Ask ten welders to turn up the weld heat, five will increase the weld voltage and five will turn up the wire feed.

[] I hope you are aware of why flux cored weld weaves in vee grooves should have limits and what those limits are.

[] The fact that many of your welders will only use one setting to weld everything is another indication of the lack of process expertise.

[] In many facilities such as ship yards and pipe shops, the weld process transition was from the stick welding to the flux cored process. Many of the welders in these facilities who are using the flux cored process will use "stick or MIG welding techniques" that are not suited to the flux cored process.

WHY DO YOU NEED THIS PROGRAM?

[] You know the cost of your NDT.

[] You know the cost of your weld rework.

[] You are not quite sure if the welders are producing maximum weld depositions rates for the application.

[] You know the cost of a poor weld reputation and weld product liability.

[] You would like your weld personnel to have an easy to remember method for setting optimum welding parameters for any flux cored application.

[] You want your weld work force to be professional in their approach to all position flux cored welding and you have to want them to provide a uniform approach to controlling the weld processes they use.

[] You know that the weld procedures you have in the office cabinet are not dealing with the real world variables (edge preps, dimensions, metal condition and environment) that daily influence the weld quality and productivity.

[] In your shop, your weld personnel will tell you 10 different ways to produce that vertical up weld. You know that their has to be a best way, a uniform approach to dealing with the unique requirements of all position root, fill and cap pass welds.

[] As you look around your weld shop, you know in the last decade your company has tried;

(a) ten different weld consumables,
(b) nine different weld power sources,
(c) eight different MIG gas mixes.

If you have been looking for a resource to establish flux cored Best Weld Practices and Process Controls this is it.



Open roots, steel backed or ceramic backed roots all require unique process considerations. Using MIG / MAG , STT, RMD, Short Circuit, or globular for the pipe root, optimum parameters and techniques are provided. Welding that ceramic backing root without weld defect formation requires special process considerations, its included.

WELD EQUIPMENT COSTS: An additional benefit of this program is to eliminate the sales induced process hype that surrounds MIG weld equipment selection. This program shows you which power source has the best weld transfer characteristic's, is the most durable and cost effective for the MIG and flux cored weld consumables discussed. This program can dramatically reduce your weld equipment, consumables and equipment maintenance costs.

 

 

When Textron had welding problems with it's Stingray Tanks, they sent Ed
to Thailand to solve the weld issues and manage the extensive weld repairs.

Ed trained the Thai army on how to do the all position flux cored and MIG weld repairs
on the Stingrays 270.000 tensile armor plates.

 

MANY MANAGERS / SUPERVISORS / ENGINEERS HAVE NEVER FELT
COMFORTABLE ABOUT UNDERSTANDING WELD COSTS.

This program provides Ed's unique simple approach to weld cost controls. The program enables engineers, supervisors and managers to simply glance at the wire feed control and instantly be aware of the welders production performance and the cost of that weld.

WORRIED ABOUT FINDING WELDERS? WORRY LESS:

When a simple method is used to educate the personnel on how to master a welding process and the equipment utilized, that program instantly improves the process confidence level of those workers and dramatically reduces the time required to create a highly effective weld work force.

Ed has provided training to thousands of workers in twelve countries. With this program you can take a worker with no previous weld experience and in less than forty hours training, enable that worker to weld all position pipe / plate welds that will consistently meet the highest global weld code standards.

THIS PROGRAM BUILDS IT'S WELD PROCESS AND TECHNIQUE RECOMMENDATIONS AROUND WELD DEFECT PREVENTION. YOU HAVE TRIED THE SALES ADVICE AND LOOK WHERE THAT TOOK YOU. WHY NOT GET REAL WORLD WELD BEST PRACTICE ADVICE FROM SOMEONE;

[] WHO HAS TESTED MIG EQUIPMENT AND CONSUMABLES FOR 40 YEARS,

[] WHO HAS ADVISED OVER 1000 COMPANIES IN 12 COUNTRIES ON HOW TO SOLVE THEIR MIG AND FLUX CORED WELD ISSUES AND HOW TO INCREASE THEIR WELD PRODUCTIVITY,

[] WHO HAS WRITTEN MORE THAN 2000 PAGES ON THE SUBJECT OF MIG AND FLUX CORED WELD BEST PRACTICES / PROCESS CONTROLS:

[] WHO HAS DEVELOPED THE WORLD'S MOST EFFECTIVE WELD PROCESS CONTROL BOOKS AND TRAINING RESOURCES.

ROOT PASS AND CERAMIC BACKING.

Where else can you get the world's best advice on welding
over ceramic backed roots and the unique process
requirements for the vee groove fill and cap passes?

 

SKILLED WELDERS: This CD requires approx. 6 hours for the classroom session and with an additional 4 hours of hands on. Utilizing the recommended procedures, practices, skills and techniques provided in the CD and the weld quality / productivity improvements will be dramatic.


PERSONNEL WITH NO WELD EXPERTISE: For the personnel who have never welded, extend the hands on training for the balance of the week. The results will amaze you. In forty hours you will have a weld work force that truly understands how to daily minimize flux cored weld rework and attain maximum weld productivity.

With 40 years of hands on MIG and flux cored weld process control expertise, five books and 30 plus articles on the subject, Ed is one of the world's leading process control experts on the flux cored and MIG processes. Ed has provided weld process control training to over 1000 companies in twelve countries. Pipelines, ship yards, power plants, nuclear plants, waste energy, refineries, light / heavy fabrication and too many auto/ truck plants.

E71T-1 - E70T-1 Gas Shielded Flux Cored Welds.

All Position Fillets. Vee Grooves. Pipe and Plate Welds.

Ed strives for weld process control simplification. You don't need a welding back ground to present this CD program, all you need to do is press "click" and let the program speak for itself. Need more information on this or any other program call Ed at 828 658 3574.

 

[] Link to a training session Ed provided on flux cored Pipe welds. Imperial Oil Alberta

[] Link to Ship Building and the consequences of Bad Flux Cored Welds

[] Link to a flux cored work shop provided by Ed to the Aker Kaverner (Philadelphia Naval Ship Yard)

For more info contact Ed at E-mail ecraig@weldreality.com.

Call Ed at Asheville North Carolina. 828 658 3574 or cell 770 330 9933.


Back to Ed's Train Resources to order and view other process control programs.

 

This group is part of the 300 ship yard welders who went
through Ed's flux cored process training program. Ed in blue in middle.

Jan 2007: Ed and Tom (blue sweaters) provided flux cored Weld Process Control
Training, for Aker. This company builds oil tankers.
Location: Excel Weld Training Center, the Philadelphia Naval Ship Yard.

 

 

 

 

Flux Cored. The CD Power Point Program Contents.
[] Everything you need to know about all position flux cored wires.

[] Why pulsed equipment or Inverters may impair those flux cored welds and which weld equipment works best with flux cored wires.

[] Why stick weld techniques cause flux cored weld issues.

[] Correct flux cored weld techniques for all position vee groove welds on open roots and ceramic / steel backing.

[] When to use fore hand and back hand.

[] How to prevent weld defects, porosity, worm tracks, lack of weld fusion, cold hydrogen cracks and hot crack's.

[] Why you should use E701-1 versus E71T-1 wires.

[] When to use MIG versus flux core.

[] The correct flux cored wire diameter for optimum weld fusion and weld deposition rates.

[] The differences between CO2 and Argon CO2 flux cored welds.

[] The correct utilization of wire feeders and guns with a great trouble shooting section.

[] Correct weld edge and plate preparation for flux cored vee groove welds.

[] How wire stick out variations can work for or against the weld.

[] Ed's unique Weld Clock Method". This process control method simplifies the required flux cored weld parameter selection for all steel and stainless flux cored plate and pipe welds. No notes required by the weld personnel as this data stays in their head.

[] Ed's unique clock method also focuses on attaining maximum weld deposition rates, and also makes it easy to figure out flux cored weld costs.

[] How the flux cored weld surface will reveal the weld internal quality.

[] With pipe and plate vee welds, use Ed's special instruction to minimize the weld defects that typically occur in the common vee groove locations.

[] Cap welds, root welds and fill passes all require unique techniques and weld settings for optimum weld quality.

[] MIG welding the pipe roots, the right way.

It took Ed over 1000 hours to develop this very unique training program.

 

Back to Ed's Training materials