The
MIG Management Book
"A
Management & Engineers Guide to
MIG Welding Quality Costs Training"
(656 pages).
MIG Weld Process Controls: When
setting MIG and flux cored welding parameters welders often "play around"
with the wire feed 
and
volt controls, evident, by the pen or scratch marks that surround the controls.
Playing around with controls has to impact weld quality, productivity and costs
, yet few weld decision makers know the optimum wire feed settings for the wire
diameter and mode of weld transfer used, even fewer welders know the wire feed
positions in which the short circuit mode ends and spray transfer commences.
Control
of the weld process is necessary if control of weld quality, productivity or costs
is your goal. This unique
book presents and expands the MIG and flux cored "Weld Parameter Clock Method".
The weld clock simplifies MIG and flux cored parameter selection for any weld.Tell
a welder to MIG weld a 16 gage part with a wire feed of 210 inch/min, 145 amps
and 17 volts and watch the welder frown. Tell the same welder to use short circuit
transfer and set the wire feed 10 o'clock with 17 cups of coffee, and watch the
welder smile.
Simplify
Weld Costs: Most
welding decision makers know the costs of welding consumables, few welding decision
makers know the costs of their daily weld deposition rates or the costs of the
common welds they produce. The weld clock method simplifies the control of MIG
and flux cored welds and this unique process control method simplifies weld costs.
Justify
Low Cost MIG Equipment:
Pulsed MIG equipment and Invertors and other costly electronic
weld equipment, will not compensate for lack of weld process expertise. Over 100
pages in this book are provided on why pulsed MIG should not be used or used with
caution for common steel welded applications. Examine why pulsed MIG may reduce
your weld fusion & productivity potential. Compare and evaluate the pulsed
MIG mode with regular MIG short circuit, globular, spray transfer, metal cored
and flux cored. There are numerous reasons why costly, sophisticated, microprocessor
power sources are not necessary to achieve optimum weld quality or productivity.
Weld equipment manufacturers have their $$$ justification $$$ for selling microprocessors
in welding equipment, in contrast I have nothing to sell, only this book, common
sense and weld advice based on 45 years MIG expertise.
E-Mail
to Ed.
Love the site, its a great
weld resource and a comforting reassurance that I really wasn't the problem. I
have been welding for 17 years and had different gases thrown in my face by salesmen
along with extensive weld advice and parameters that just didn't seem to make
sense, not to mention all the "learning curves" that I seemed unable
to attain. With your Management / Engineers book, I finally have found the process
control book that I need.
Regards.
Kevin Gough.USA.
Robotics:
The North American automotive industry spends over a billion dollars each year
on robot MIG
weld rejects and rework. This industry can anticipate an extensive increase in
its MIG welding problems as it expands it's use of extruded thin steel and aluminum
parts and strives to MIG weld, thinner, coated, high strength carbon steels. This
book addresses the robot weld production and quality problems, and provides the
weld solutions.
Over
140 pages of welding solutions to robotic MIG welding applications are provided.
Reduce robot down time, fix arc instability, eliminate weld burn through,
under cut, crater issues. Ensure consistent weld fusion, improve arc starts, eliminate
weld spatter, reduce wire burn backs to the tips and unnecessary contact tip replacement.
This is the first global book that provides advice on how
to achieve faster than traditional robot weld travel rates and
the unique "Seven Steps to Weld
Process Control Program" which is designed specifically for robot MIG welding
cells, will assist the weld decision maker in attaining consistent robot quality
& productivity.
E-Mail:
I spoke with you on the phone a couple of weeks ago. Well contrary to the beliefs
of my coworkers I must say your concepts on GMAW are worth trying. Your story
of reading weld literature and finding it was not as it seems inspired me to do
the same. Over the last three years all I have done and continue to do is read
from a variety of welding resources. So this past week I have focused my study
on the "hands-on" practical aspect. Its amazing what you learn from
having your nose in the arc rather than observing from out side a fence. From
this approach I now fully understand how and why globular transfer is not a reliable
mode of transfer, especially when utilizing it for high travel speeds (50- 70imp).
Tonight thanks to your books I was able to figure out how
you achieved robot speeds of 70 to 100ipm in spray mode. I went snooping
around the plant and found an old style of gas diffuser that was shorter than
our common ones. I then took your advice from your WELD MANAGEMENT AND ENGINEERS
book and cut about a 6 mm off the end of a tip. With having the tip recessed in
to nozzle allowed for a longer stick out dropping the amperage but still within
the spray range. The longer wire stick out permitted me to run higher WFS (deposition
rate) without the extra amperage that would cause unwanted weld defects like weld
burn through. The spatter was minimal and easy to remove. Also the recessed tip
and diffuser were spotless. A
Ed
Thanks for your contribution to my weld education.
Matt Finn. USA.
E
Mail to Ed.
I have just read your Chrysler Neon article regarding the cross members and
self shielded flux cored wire issues. I fully endorse your views and comments.
Its a shame that many "weld engineers" in the automotive industry lack
the actual knowledge and skills to fulfill this critical role. I myself am a welding
engineer for a tier one supplier to the UK auto industry and see this too often.
As an engineer and also time served boilermaker, I feel that there is a tremendous
lack of MIG weld process knowledge and experience with the welding and engineering
personnel in the auto industry. I must also thank you for your SDs / books especially
the " Management & Engineering Guide to MIG"
We as a company refer to them regularly. Cheers
PL
- England.
Ed
set the robot welds for Volvo Cabs, the Corvette, Harley bike
and Ford 150
truck frames.
E-Mail
Ed
I wanted to send update about that E-Town 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 per-hour and the majority required extensive weld rework.
Thanks to your weld process and consumable recommendations, your training books
and Robot Process Control Training Program, today the results from our employees
are staggering. Yesterday this plant hit very close to a record of 76 truck frames
per hour. We daily attain our average goal of 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 F-150 truck
frame line.
Many
thanks!
R
Good. A Grateful Employee of
Dana Corporation.
E-mail
From:
Ed.
Tenneco has plants all over the world. We
have been very enlightened by your " Robot MIG Weld Process Control"
training book and your "Seven Steps to Robot MIG Weld Best Practices and
Process Controls Workshop" We are slowly implementing your process control
and best practice concepts to the shop floors.
Tom
Plummer:Tenneco .USA. 2007
E-Mail
to Ed.
I
am very interested your guide book, “A Management & Engineers Guide to
MIG Welding Quality Costs Training” My friend who works for Dana - Structural
Solution Group in the United States suggested we get this book.
Regards,
Kanit. Product Engineer. Auto / truck frame manufacturer. located in Thailand.
Note: In the nineties, Ed was the Robot
Welding Mgr. for ABB. Robotics Div, North America. Later as a consultant he visited
hundreds of companies in 12 countries fixing Fanuc, Panasonic, Motoman,
Cloos, OTC, ABB robot welding issues
Pipe
and Pressure Vessels, Ship yards Oild Platforms or Construction Projects:
Weld procedures may be qualified, however once you get in that weld shop or out
on the constrution site, in the world of numerous weld variables you will find
that optimum MIG or flux cored welding practices and process controls are rare
and the weld focus is always placed on the "welder's skill."
HOW
NOT TO PRODUCE A CLAD WELD
2008:
Compare what lack of weld process controls achieves
from the above photo (clad
welds on boiler water wall tubes)
to what can be attained, below.
2005:
Ed's Pulsed MIG clad welds. Inconel 625. Vert down. Single pass.
The
SMAW (stick) pipe weld process requires extensive skill, yet
this process also requires minimum weld 
process
expertise. In contrast MIG welding on pipe requires "extensive weld
process expertise". Who provides the welder with the MIG or flux cored weld
process expertise they need when they change from stick to MIG or flux cored welds?
The lack of process expertise and the extensive lack of pipe weld fusion
that goes into pipe welds can have serious liability consequences for pipe shop
owners. This book provides unique, MIG pipe weld data developed by the author
with one goal in mind, minimize lack of pipe weld fusion.
Ed
developed 4 of the top 10 MIG gas mixes sold in the USA.
The
costs of Sales Advice: Weld
sales advice often negatively influences the selection of weld equipment and consumables.
Many weld gas mixes are selected based the advice of a salesman. The gas mixes
are rarely selected based on arc physics, weld oxidation, or weld energy potential.
The most popular gas mixes sold the North America are argon-CO2-oxy tri-mixes.
The tri-mixes are a poor choice for many common applications. Ed developped 4
of the top selling gas mixes used in North America. Cut through the gas product
hype that surrounds the 40 plus available gas mixes, and read Eds unique gas mix
solutions for manual and mechanized carbon steels, stainless and nickel applications.
Weld decision makers should always be able to differentiate practical weld advice
from, costly product bias, or sales hype.
If
you intend to make a career in the weld industry, this book will ensure
you
are on the fast track to optimum weld quality and productivity.
The
MIG Management Book
"A
Management & Engineers Guide to
MIG Welding Quality Costs Training"
(656 pages).
Ensure
you check out Ed's other robot control books and CD training resources,
click
here to go back to Ed's training materials.
