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.


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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.