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Any weld facility that provides this type of weld process control training should anticipate an immediate dramatic decrease in weld rework and an extensive increase in weld productivity.

THIS YEAR IN NORTH AMERICA OVER 200 MILLION DOLLARS WILL BE USED FOR UNNECESSARY FLUX CORED WELD REWORK. AS LESS THAN 10% OF THE PIPE AND PLATE WELDS WILL BE SUBJECT TO NDT AND REQUIRE EXTENSIVE COSTLY WELD REWORK, IT MAKES YOU WONDER ABOUT THE LEVEL OF FLUX CORED WELD PROCESS EXPERTISE IN THE SHOPS AND THE QUALITY OF THE 90% REMAINING WELDS.

Too frequently the well established weld procedures in most weld shops do not provide weld personnel with the unique process data that can compensate for the many variables that affect the welds. This program and all of Ed's training / educational resources examines the common root causes / variables and develops the the weld process controls, techniques and skill solutions that can dramatically lower your weld rework potential and increase the weld productivity.

In this work shop you not only get to learn the unique process solutions in the class room, you can see or produce the results in the hands on training part of the program.

[] PIPE / PLATE ROOT CAUSE AND SOLUTIONS: Weld procedures typically don't deal effectively with inconsistent or poor weld edge preparations, and variable root openings that are common to every pipe and plate shop. This work shop deals with the root causes for flux cored weld failures and provides highly effective, process , techniques and skills weld training solutions that are taught in both the classroom and demonstrated in the weld shop.

[] PIPE / PLATE ROOT CAUSE AND SOLUTIONS: The all position root, hot pass, fill passes and cap pass in each vee groove weld layer, offer unique weld issues and challenges. This program provides the optimum flux cored weld process and technique requirements that will minimize weld cracks, and reduce the potential for lack of weld fusion, slag inclusion and porosity. We especially focus in the vee groove weld's hot pass and first fill pass locations as this is where most of the all position vee groove weld defects occur.

[] ROOT CAUSE AND SOLUTIONS: WELD PROCESS EXPERTISE:

[] In many facilities such as ship yards and pipe shops, the process transition was from the stick welding to the flux cored process. Many welders using the flux cored process will use "stick welding techniques" that are not suited to the higher weld energy, higher weld deposition rate flux cored process.

[] The fact that 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.

[] 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 your organization.

[] Few global companies that weld, use ceramics for root backing. Flux cored welds on ceramic backing require unique weld techniques and settings that are rarely found in the weld procedures sitting in a cabinet in the quality managers office. This program provides the missing link common to all weld shops, lack of flux cored / MIG process control expertise.

In the hands on section of the work shop, if you wish we will demonstrate or you may weld using the best weld wires, the best weld equipment, the logical gas, optimum weld data and techniques. The hands on evidence and results will convince you.

GLOBALLY, 100 PLUS MILLION DOLLARS WILL BE WASTED ON OVER PRICED MIG EQUIPMENT WITH UNNECESSARY ELECTRONIC BELLS AND WHISTLES AND MILLIONS MORE WILL BE SPENT ON REPAIRING WELD EQUIPMENT THAT CAN BARELY GET TO THE END OF IT'S WARRANTY PERIOD.

[] SAVINGS FROM WELD EQUIPMENT COSTS: Most pipe and pressure vessel shop will purchase weld equipment influenced by sales bias. The equipment typically may have useless bells and whistles, and the equipment rarely makes it through the warranty period without the need for repair.

Most ship yards will pay one to three hundred thousand dollars each year to replace / repair MIG weld equipment that should be lasting two hundred percent longer. Find out how to reduce your equipment costs by at least 50% and dramatically reduce those weld equipment maintenance head aches.

FEW GLOBAL COMPANIES ORDER THE CORRECT WELD CONSUMABLES THAT ENABLE MAXIMUM WELD PRODUCTIVITY AND ASSIST IN REDUCING THE WELD REWORK COSTS.

[] In many companies I see the wrong size electrode wire selected, the wrong type of consumable, the wrong gas, Every flux cored wire manufacturer makes what they think is their unique E71T-1 all position weld wire. We show you the weld consumables and equipment that gets the job done with the highest possible weld quality at the lowest possible costs.

SEEING IS BELIEVING: THIS IS ONE WORK SHOP YOU WILL SPEND 50% OF THE TIME IN THE CLASSROOM AND THE OTHER 50% APPLYING OR VIEWING THE RECOMMENDED CONSUMABLES, PROCESS DATA AND RECOMMENDED TECHNIQUES TO THE MOST DIFFICULT VEE GROOVE APPLICATIONS.

[] The weld cost focus in many weld shops is on the costs of the weld consumables rather than on the costs of the welds, the deposition rates or real world weld production potential. This work shop provides managers, engineers and supervisors a simple solution to attaining optimum weld productivity and a simple method to understanding and controlling weld costs.

WHEN YOU LEARN THE PROCESS CONTROLS PROVIDED IN THIS COURSE, YOU LEARN A SIMPLE METHOD TO UNDERSTAND AND CONTROL THE COSTS OF YOUR WELD.

[] OUR WELDERS HAVE ON AVERAGE BEEN STICK WELDING SHIPS, CARS, TRAINS, TRACTORS OR PIPE LINES FOR 20 YEARS, WHY DO THEY OR THE SUPERVISORS, ENGINEERS OR MANGERS NEED FCAW PROCESS CONTROL TRAINING?

Flux cored is a high energy, high weld deposition weld process. In contrast, SMAW is a low energy, low weld deposition rate process. SMAW requires minimal process expertise. SMAW is all about the welder's skills and slow weld speeds enabling the welder time to manipulate the electrode either side of a vee groove and pinpoint the small fast freeze weld puddle.

In contrast to SMAW, the flux core process is about understanding the wire feed and voltage settings and their suitability to the application. This is a process in which wire stick out changes can change the weld mode of transfer or provide a dramatic change to the weld energy level. With the FCAW process the use of a weld voltage that is one volt too high or low can create weld instability for the welder. This process results in higher weld speeds requiring different weld techniques and different weld profiles. The bottom line, FCAW is a very different process than SMAW, its a weld process in which all weld personnel including managers, supervisors, welders and QA people can benefit from Process Control Training.

When we train, we provide a truly unique simple training approach that after 4 hours, weld personnel who have never before welded will master the process and optimize the parameters with out playing around with the weld controls. This training will quickly turn a novice welder into a welder that can meet all position weld code requirements. For the skilled weld personnel the training results will be immediately measured in a dramatic cost reduction in weld rework and increased weld productivity.

WITH ED'S UNIQUE SIMPLE APPROACH TO PROCESS CONTROLS YOU WILL WORRY LESS ABOUT GETTING SKILLED WELDERS OR IMPROVING YOUR EXISTING WORK FORCE. AS A WELD DECISION MAKER YOU KNOW ITS LOGICAL THAT ALL WELDERS, QA PERSONNEL, TECHNICIANS, ENGINEERS, SUPERVISORS AND MANAGERS WALK THE SAME PATH TO WELD QUALITY OPTIMIZATION AND WELD COST REDUCTION.

IDEAL FOR SHIP BUILDING, REFINERIES, OIL RIGS, BRIDGE BUILDING, STRUCTURAL AND HEAVY EQUIPMENT COMPANIES, PRESSURE VESSEL AND ALL PIPE SHOPS.

Location: The Excel Weld Training Facility.
In the Philadelphia Naval Ship Yard Facility.

We can also do this at your facility

Cost: $985 per person, a 15% discount for more than 3 attendees.

Date: The last week of every month starting in April:

For a MIG or Flux Cored weld process control work shop at your facility or at the Excel Training Center, or for more information on unique, highly cost affective Flux Cored or MIG work shops, E-mail Ed at ecraig@weldreality.com, or call day or evening, Eastern Time USA.

Phone Ed at 828 658 3574, cell 770 330 9933.

If you believe the weld personnel in your organization have control of the FCAW process, they should readily pass this Flux Cored Weld Quiz:

Link to a flux cored pipe training program Ed provided for Imperial Oil Alberta

Link to Ship Construction and bad flux cored welds