If weld quality is your first criteria, remember,
Pulsed MIG and regular TIG cannot compete with TIP TIG

"It's logical that that the constant weld energy attainable from CV MIG spray transfer, is of course a prime attribute in attaining consistent weld fusion and consistent weld transfer during high speed welds".

A PROCESS INVENTED BY ENGINEERS WHO DID NOT UNDERSTAND WELDS:
If you read the early 1980s research papers published on the newly developing pulsed MIG process, one of the prime justifications for the development of the pulsed process for carbon / stainless steel welds was to have a weld process suited to making weld in all positions.

1990s. Photo on right. Ed testing a pulsed MIG, STT over head weld, on a 16 inch gas pipe pipe root.

PULSED FACT: Since the pulsed MIG introduction in the nineteen eighties, when welding many steel applications vertical up and over head, the pulsed MIG process has not been able to compete with the all position gas shielded flux cored wires developed in the 1970s - 1980.

It must annoy MIG equipment manufacturers who see great profits from the sales of their useless bells and whistles MIG equipment, that the $1.80 lb, E71T-1 flux cored wires can attain superior all position weld results when used on low cost, durable, $3000, CV, MIG equipment little changed since it was developed in the 1960s.

If you want the best weld quality with all position welds, you improve the process that has always provided the best all position weld quality. That process is called TIP TIG

IT'S NOT ROCKET SCIENCE. WHEN PURCHASING MIG EQUIPMENT, WELD SHOP FOCUS HAS TO BE ON THE WELD QUALITY ATTAINED AND THE COST OF THE WELDS PRODUCED.

If before 2006, you were a frequent user of the pulsed weld process and you were welding carbon steel applications, it's likely in contrast to the traditional, CV lower cost equipment and the spray transfer weld mode, you would have been producing steel welds on parts > 4 mm with the following detriments;

[] Your pulsed MIG welds were producing Inferior weld fusion,
[] Your pulsed MIG welds were producing unnecessary weld porosity,
[] Your pulsed MIG welds, especially with automation increased arc instability,
[] Your pulsed MIG welds were made with less weld deposition rate potential.

In 2013, if you are using pulsed MIG, it's likely you are still having the above mentioned weld issues.

Of course like many managers and engineers, you may also have been using pulsed MIG equipment for the last decade and were not aware that you were overpaying for the MIG equipment bells and whistles and that this equipment was influencing both the weld quality and production. Welcome to weld reality.

When examining new MIG weld technology, one should remember that the conventional short circuit and spray transfer modes that were developed and perfected over five decades, also offer unique weld benefits. However the short circuit and spray weld benefits are rarely derived from weld personnel who have to "play around" with weld controls. To attain MIG process benefits from low cost MIG equipment requires MIG process expertise and that's a rarity in many weld shops.

 

Ed optimized both robot and manual
MIG welds for more than a 1000 companies.

A FEW OF ED'S MIG ROBOT WELD PROCESS OPTIMIZATION PROJECTS. FORD F150 FRAMES - VOLVO CABS - CORVETTE FRAMES - HARLEY FRAMES - NEW BEETLE SEATS AND ED ALSO ESTABLISHED THE ROBOT WELD FOR THE WORLD'S LARGEST CATERPILLAR TRUCKS.

Click here. Robot Weld Best Practices / Process Control materials.

 

WELD PROCESS CHOICES ARE MADE MORE DIFFICULT, ESPECIALLY
WHEN WELDS SHOPS ARE DAILY IMMERSED IN WELD PROCESS CONFUSION:

Many of you have worked or still work in weld shops in which the managers, engineers and supervisors are not aware of the real cost of that common
MIG or flux cored, 1/4 (6 mm) fillet weld.

Many of of you have worked in a weld shop in which AWS inspectors daily criticize MIG and flux cored weld quality, yet these individuals lack the weld process control expertise necessary to provide the settings that would improve the welds.

Many of you have worked in weld shops in which the majority of weld personnel daily "play around" with their MIG or flux cored weld controls?

Many of you have worked in weld shops in which the management, supervision and engineers have an umbilical cord attached to the local weld sales rep. This is the guy has an open door invitation to come in and demonstrate the latest MIG gas mix, weld consumable or power source?

Many of you will work in shops where you know the weld decision makers who selected the costly, sales driven pulsed MIG equipment or unnecessary three part gas mixes, were typically not qualified to make rational MIG weld process / equipment selection decisions.

This lack of process control expertise is common in weld shops in which the management, supervisors and engineers have minimal ownership of the weld equipment, processes and consumables utilized on their weld shop floor.

Weld Process Controls should always start in the front office:

From an Ed Craig report to a General Motors plant. 2001:


When your managers and engineers recognize that Weld Best Practices and Weld Process Controls knowledge is far more important than the purchase of costly, useless electronic weld equipment with bells and whistles, your plants will take a giant leap towards establishing optimum robot weld quality and productivity.

One customer I assisted around 2005, manufactured carbon steel street lamps 11 to 7 gage. These are extensive yet simple manual weld applications. On the end of the lamps a large heavy flange is welded. The flange mounts the lamp to the floor. The flanges were 13 mm thick. There was also a weld around the pole access box, (gage material) located near the flange.

I hope the following comments on Pulsed MIG and the weld process comparisons with traditional MIG short circuit, spray and the flux cored process, will provide you or your organization a different perspective on the rationalization of the purchase of pulsed MIG weld equipment and the need for process expertise.

Management should ask this question more frequently.

To Pulse or not to Pulse, especially if they want to
produce welds without fusion issues and cracks.

 

MILLER MAXTRON AND INVISION POWER SOURCE PROBLEMS:

E-mail. From a manufacturing manager at Hayes Lemmerz. Hayes. Ed Hayes is a global manufacturer of car and truck wheels. We use the Pulsed MIG process for most of our wheel welds. Since we introduced the Miller Maxtron and Miller Invision equipment to our automated, MIG weld production lines, we have had extensive, weld production and rework issues. The typical wheel pulsed weld problems that we experienced with the Miller equipment were;

[1] welds skipping, resulting in weld areas that contain
unacceptable and inconsistent thin welds,
[2] missed welds,
[3] welds with inconsistent weld penetration,
[4] weld globs,
[5] unexplained weld porosity,
[6] Inconsistent weld surface appearance,
[7] inconsistent weld undercut,
[8] numerous arc starts, weld crater and weld tie in issues,
[9] numerous wire burn back issues,
[10] extensive weld equipment break downs.
Please give us a call we would like to utilize your expertise.

At the request of the Hayes management, I evaluated the pulsed MIG weld issues and quickly revealed to the Hayes management the root cause of their extensive weld issues and that root cause was the Hays management, the engineers and weld equipment. For the rest of this story click here.

Welding steels? I now consider myself an old fart who has evaluted pulsed MIG for more than 25 years and s its a rare event, I will only use or recommend "manual" pulsed MIG when it delivers real world weld quality - productivity benefits and can therefore pay the bills.

FOR THOSE OF YOU THAT ARE LESS THAN 40 YEARS OF AGE AND THINK I AM AN OLD FART STUCK IN A 1970 MIG EQUIPMENT TIME WARP. MY WIFE WOULD AGREE THAT I AM OLD FART, HOWEVER I AM AN OLD FART THATS ASSISTED OVER 1000 COMPANIES WITH THERE WELD ISSUES, AND BY THE WAY THAT'S NOT MY PICTURE ON THE LEFT.

in the few years I have been in this business I have set some of the world's most sophisticated automated and robot weld applications and as the corporate weld manager with ABB, North America Robot Div, I believe I have a little knowledge about robots and their weld process requirements.

As someone who has been in so many weld shops in 13 different countries, I believe I have a good grasp of weld shop culture and weld shop management.


In 2006 I was hired as the corporate weld manager with WSI, (Aquilex) . This is a company known for it's expertise in Nuclear plant weld repairs and for cladding approx 75% of the world's power plant and waste energy water wall boilers. WSI at that time used over one million pounds of stainless and inconel weld wires on automated pulsed MIG clad welds on the water wall tubes. This ASME clad application actually attained unique weld benefits from the pulsed MIG process.


I was hired by the WSI engineering manager as he believed while his automated weld equipment had evolved past the complex water wall clad welding needs, the actual clad weld results from the pulsed MIG equipment and field weld personnel left more than a lot to be desired.

The pulsed clad weld quality left extensive lack of fusion, poor weld overlaps, extensive surface weld issues and unnecessary excess welds with the $26/lb, inconnel wires. A major issue with the power plants was the clad water wall
welds too often applied too much weld heat that had a negative impact on the boiler wall longevity.


In less than three months of pulsed MIG equipment evaluation and weld process development, I developed new pulsed MIG clad weld practices and procedures that dramatically improved the inconel - stainless weld quality and lowered the weld heat. The inconel clad welds I produced, (untouched clad weld photo above) delivered over 15 lb/hr and reduced the amount of clad water wall welds required per square foot by approx. 28%. Remember this was a company that purchased over a 1 million pounds of clad weld wire for it's water wall clad applications. For this application I required unique pulsed parameters and had to develop a unique pulsed program. These were parameters that could not be attained with the Miller, Lincoln or ESAB pulsed MIG equipment that was part of the WSI pulsed MIG equip evaluation.

The important thing with any clad application is minimize the weld dilution. In contrast, the important thing with welding is attaining consistent, optimum weld fusion. What make Pulsed MIG a poor choice for many weld applications, makes it a good choice for specific clad applications. The above clad welds would not be possible with the spray transfer mode.

I started my weld journey MIG welding tractors at Massey Ferguson, Manchester UK, in the early 1960s. I wrote my first MIG weld process control article in the late 1970s. Exited at the potential of Pulsed MIG, I wrote my first pulsed MIG article for the USA. Weld Journal in the early 1980s. During the last 3 decades I Have written four books on MIG weld best practices - process controls and had more than 30 weld process control articles published. In this time period I was also the Weld Product and Training manager for four of the world's largest weld equipment manufacturers and suppliers.

THE BOTTOM LINE, I BELIEVE I AM QUALIFIED TO HAVE AN OPINION ON WELDS.

$10.000 for erratic pulsed MIG equipment on the left.
$3000 stable CV MIG equipment used on the right.

What the weld equipment manufacturers MIG equipment may
produce, and what most welders will never see.

As the above MIG pulsed current - weld voltage graph indicates, on the left you have a highly sophisticated Panasonic pulsed MIG power source, and on the right you have a similar parameter graph with a low cost, traditional CV MIG power source.

TRANSFERRING THE PULSED MIG WELD WIRE IN WELD DROPLETS OR A WELD STREAM, WHO CARES?
Typical concerns with pulsed MIG equipment when welding steel components.

[] Pulsed Weld Fusion: A primary issue with the pulsed MIG weld fusion is this process spends 50% of it's time at a typical back ground weld current of < 100 amps.
[] Pulsed arc stability is important for weld quality. Pulsed MIG drops need to transfer without interuption. Pulsed welds are often influenced by the power source electronics which cannot deal with short arc lenths and wire stick out variations and the many weld - part (like mill scale) variables that can influence the weld transfer.
[] Pulsed MIG and vert up welds. An issue that few weld shops think about. There is a reason why TIG welds produce the best weld quality on all position pipe welds. TIG provides constant high weld energy with very low deposition rates which require very slow weld speeds. High energy and low speeds is beneficial in attaining consistent weld fusion. In contrast, pulsed MIG provides fluctuating, moderate weld energy with pipe weld deposition rates that can be 700% higher than TIG. The pulsed MIG deposition leads to much greater weld mass and faster weld speeds than TIG, this reduces weld fusion potential.
Note: The best weld process for pipe welds is revealed at www.tiptigusa.com.

FOR DECADES THE WELD INDUSTRY SUFFERED TREMENDOUS WELD COST CONSEQUENCES FROM THE ERRATIC PERFORMING PULSED MIG WELD EQUIPMENT.

2013: During the last two to three decades, most of the erratic pulsed MIG equipment required numerous
E-Prom and circuit board changes, yet as far as
I am aware, not one of the major pulsed weld equipment manufacturers ever did a pulsed MIG power source product recall.

AN INDUSTRY THAT LACKS MIG WELD PROCESS CONTROL EXPERTISE IS AN EASY CUSTOMER FOR WELD EQUIPMENT MANUFACTURERS THAT MAKE FAULTY MIG EQUIPMENT, OR MAKE WELD EQUIPMENT WITH BELLS AND WHISTLES THAT PROVIDES NO STEEL OR ALLOY STEELS WELD BENEFITS.

IN A DIRTY WELD SHOP, WELD EQUIPMENT DURABILITY USED TO MEAN SOMETHING:
Traditional CV MIG weld equipment used to last 10 to 20 years, and the weld equipment repair costs carried out by the plant's electrician was typically a few hundred dollars. Today many of the companies who have purchased pulsed MIG equipment will pay $2000 to $5000 for pulsed MIG weld equipment repairs, and these repairs are too frequently required before the weld equipment is 48 months old.


2013: Statistics that the major weld equipment manufacturers wont discuss.

[] WHAT PERCENTAGE OF PULSED MIG EQUIPMENT LASTS
BEFORE IT'S WARRANTY EXPIRED?

[] WHAT THE AVERAGE LIFE OF A PULSED POWER SOURCE IS?

[] IN A FIVE YEAR PERIOD, WHAT THE AVERAGE
REPAIR COST IS FOR THE PULSED MIG EQUIPMENT?

[] HOW MANY COMPANIES WHO USE PULSED IN ROBOT CELLS, HAVE HAD
TO PURCHASE AN ADDITIONAL PULSED POWER SOURCE SO THEY HAVE A SPARE?

[] HOW MANY HIGHLY QUALIFIED MAINTENANCE ELECTRICIANS FEEL
COMFORTABLE ATTEMPTING TO REPAIR A PULSED MIG POWER SOURCE?

[] HOW MANY COMPANIES REALLY ATTAINED REAL WORLD BENEFITS FROM
THAT NEW COSTLY PULSED POWER SOURCE?

It's a sad reality that many companies will pay $3000 to $5000 for pulsed MIG weld equipment repairs, which is more than the cost of a new CV MIG power source and wire feeder.

Remember that traditional, CV power source. It's that low cost weld power source which can provide optimum MIG - Flux Cored weld productivity and quality, that is if you provide the weld personnel with weld process control training. This is the MIG power source that should last one to two decades without repairs.

What helped the low durability, higher cost, more erratic, lower weld energy pulsed MIG process become so popular in the last two decades?

[] In contrast to producing traditional CV MIG equipment, when manufacturing pulsed MIG equipment, the power source manufactures can reduce their alloy, labor and shipping costs

[] Like the auto industry, all MIG equipment manufactures are aware that when you add electronic bells and whistles to the weld equipment you can dramatically increase the MIG weld equipment prices.

[] What motivates the weld sales rep? When you sell products with lousy gross margins your only hope is to sell weld equipment in the high dollar range and pulsed MIG equipment typically sells for 100 to 200% more than traditional MIG equipment. Also its beneficial to any sales organization that if the durability of your weld equipment is reduced, the customers will have to purchase more equipment.

 

Don't try this titanium weld (video below) with your
pulsed MIG or regular TIG. the welds will fail.


Titanium Welds: TiP TiG versus the regular TIG process.

TRADITIONAL ORBITAL TIG ON GRADE 2 TITANIUM	MANUAL TIP TIG ON GRADE 2 TITANIUM
While using the slow manual or automated regular TIG process, there is always concern about the oxidation effects on Titanium alloys. Typically all position, manual or mechanized titanium TIG welds on parts > 3 mm will be carried at weld speeds in the 2 to 6 inch/min range. To protect those low speed, high heat welds, trailing shields are a critical weld requirement to minimize the effects of oxidation. If trailing shields are not used, the weld shop uses extra large shielding nozzles and stops the weld frequentlty to get the part under a specific temperature. When welds are sensitive to oxidation you know weld rework and weld porosity will be an issue. The high TIP TIG weld speeds and weld TIP TIG weld agitation will produce the highest quality, cleanest titanium welds.	With either the manual or automated TIP TIG process, TIP TIG titanium weld speeds will be much faster. The higher TIP TIG weld speeds will typically be in the 9 to 40 inch/min range. The high TiP TiG speeds enable most titanium welds on parts > 4 mm to be complete, none stop and produce produce 100% silver color without the use of a trailing shield. TiP TiG enables better than TIG quality at MIG travel rates. This weld was made at 24 inch/min. If your organization uses regular TIG on Titanium, you will be pleased to know that with TIP TIG, most manual or automated titanium welds will typically be done 100 to 300% faster with superior weld quality and the lowest possible weld heat. visit www.tiptigusa.com.

 

AN IMPORTANT WELD COST REDUCTION MESSAGE TO ALL DEFENCE CONTRACTORS: As reported in the 2009. September. AWS. Weld Journal, the above (left frame) orbital Titanium welds were carried out on US Navy ships. On one ship approx. nine orbital TIG weld units were used to weld CP Grade 2, titanium welds. The titanium welds were required on more than 12000 feet of titanium pipe which was used on each ship.

Typical automated weld travel rates from the costly orbital weld equipment was 3 - 4 inch/min. If they had selected the TIP TIG process on the orbital units, the TIP TIG welds would have been made at minimum weld speeds of 12 to 25 inch/min producing a dramatic reduction in weld heat input, (less chance for oxidization) with no weld quality issues or costly weld rework concerns. It's also reality that with the TIP TIG weld benefits, these titanium welds could be made with the same quality and productivity with manual TIP TIG welders instead of that costly automated equipment. You don't have to be an accountant to figure out the dramatic equipment and labor cost reductions (over 2 million dollars on this one weld project) if the engineers had look forwards instead of back wards.

Any manuafacturing manager who is worth a pinch of salt, knows that if it sounds complex, it likely should not be in a weld shop In an industry that does not think twice about playing around with a 50 year old, two control, traditional CV, MIG power source, we have the following BS?

|

 

< 2010. DURING THE LAST TWO PLUS DECADES OF SLOW PULSED EQUIPMENT DEVELOPMENT, (THANK GOD COMPUTERS EVOLVED AT A MUCH FASTER RATE), MOST PULSED MIG EQUIPMENT WAS PROVEN TO PROVIDE NO WELD BENEFITS FOR MANUAL MIG OR HIGH SPEED ROBOT WELDS ON CARBON / LOW ALLOY STEEL APPLICATIONS, YET THE MAJORITY OF NORTH AMERICAN WELD SHOPS COULDN'T BUY THEM FAST ENOUGH.




IS THIS THE NEXT BS YOU WANT TO SEE AND HEAR IN YOUR WELD SHOP?

The unique $12000 MIG power source called called X-MIG, is controlled by a palm pilot. This power source offers artificial intelligence with adaptive synergic controls. You know you cannot control a weld without wave forms and
X-MIG provides five million wave form variations.

With X-MIG you get fuzzy, weezy, fuzzy woozy logic and triple AC pulsed on triple DC pulsed. X-MIG also provides a refined super adaptive turbo pulse which gives
the arc an additional boost. included with
the X-MIG, is a modified short circuit mode called MSC.

Your new, X-MIG power source can also be hooked up to the welder's cell phone or I-Pod, and controlled if you feel the need with the palm pilot through the ethernet.


X-MIG comes with a two week warranty, (check small print for warranty clauses) and there is no return policy. By the way as we feel we are not responsible for the performance of this power source we feel you should be aware that it has never been field tested correctly. To order this unique, useless MIG equipment, which cost the price of a small car, contact the industry leaders in new weld technology, at askaweldsalesman.com

Could your weld shop produce a better weld than this?

Ed made the above Robot weld and the manual MIG weld below, using spatter free, MIG spray transfer from a $3,500 traditional, CV. MIG power source that had no electronics.

CV MIG Spray weld.

The low cost, durable, 400 amp, CV MIG power source I utilized on the above spatter free spray weld, was developed four decades before Wave Forms and Fuzzy Logic became weld weld sale's buzz words.

 

THE MORE COSTLY THE PULSED MIG EQUIPMENT, THE MORE COMPLEX AND MORE EXPENSIVE THE MIG WELD EQUIPMENT REPAIRS. .WHEN THE MAINTENANCE SUPERVISOR SAW THE NEW PULSED MIG EQUIPMENT, HE REALIZED HIS ELECTRICIANS WERE SIMPLY NOT CAPABLE OF FIXING THE MIG EQUIPMENT.

THE SUPERVISOR HAD A DIFFICULT TIME FINDING A LOCAL EQUIPMENT REPAIR SHOP THAT COULD PROVIDE THE NECESSARY ELECTRONIC PULSED WELD EQUIPMENT REPAIRS WITH A QUICK TURN AROUND. TO MAINTAIN HIS DAILY ROBOT WELD PRODUCTION. HIS COSTLY SOLUTION WAS TO ORDER ANOTHER 4 PULSED MIG UNITS AS SPARES.

To purchase MIG equipment wave forms you don't need, how much will your company this year budget for new pulsed MIG equipment and the annual pulsed MIG weld equipment repairs? Two weeks after the three year old warranty has elapsed on that pulsed power source, you could end up with a pulsed MIG weld power source repair bill that is in the $2000 to $5000 range. The bottom line after that expensive repair, that three year old pulsed power source is the equivalent of a 10 year old car and you know what direction that power source is heading.

 

TWO QUESTIONS YOU COULD ASK
YOUR PULSED MIG EQUIPMENT MANUFACTURER.

[1] YOU ADMIT YOUR PULSED EQUIPMENT HAS HAD MANY ELECTRONIC ISSUES, YET I CANNOT RECALL YOU INFORMING US ABOUT THOSE FAULTS OR PROVIDING COMPENSATION FOR OUR WELD ISSUES OR PROVIDING WELD EQUIPMENT RECALLS.

[2] AS WE RESENT BEING A TEST LAB FOR YOUR EVOLVING, ERRATIC WELD EQUIPMENT, WOULD IT BE POSSIBLE FOR YOU TO THOROUGHLY TEST YOUR NEXT NEW MIG EQUIPMENT WITH PERSONS WHO HAVE PROCESS / APPLICATION EXPERTISE BEFORE YOU PRESENT IT TO THIS WELD SHOP?

Arc characteristics a minor detail for some
in the welding industry .

PULSED MIG EQUIPMENT PERFORMANCE:

As this MIG volt / amp graph of a 2004 PANASONIC pulsed MIG POWER source indicates, the weld current (black) and voltage (red) are anything but stable and the volt current spikes are unnaceptable.

Arc and weld energy stability with pulsed weld equipment is something that should be a concern for any weld individual that understands the importance of attaining consistent weld energy for consistent weld transfer and consistent weld fusion.

High pulsed MIG wire feed rates can lead to excessive pulsed frequency resulting in high peak current weld content, leading to excess weld fluidity and agitated weld puddles.

 

Pulsed MIG versus MIG Spray. 0.045 (1.2mm) steel wire set at 550 ipm.

Pulsed MIG welding Torque Converters:



This costly LINCOLN POWER WAVE,
was not up to the following simple wheel weld challenge,

2004. Another Pulsed MIG Problem from Miller and I was wondering, do those guys at Miller know what defines a good weld? and do they ever test their pulsed MIG equipment before they release the new models?

2004: This time my pulsed MIG application was a major tier one manufacturer of stainless exhaust coupling and flexible fittings as used in the auto / truck industry. The tight tolerance, stainless parts, are rotated in an automated Bancroft welding machine with the single MIG gun stationary. The stainless MIG welds were made inside the flange. With these automated parts I was again provided the opportunity to evaluate pulsed MIG versus traditional spray.

To weld the stainless coupling parts, the manufacturer had selected Miller Invision pulsed MIG equipment and the weld transfer mode utilized was the pulsed MIG mode. The 0.045 (1.2mm) 300 series stainless weld wire was set at what should have been an an optimum, conservative pulsed wire feed rate of 300 ipm with optimum weld volts. After welding each part, the parts were leak tested. The pulsed welds looked good, yet the average weld rework as revealed by the leak test was over ten percent.

To fix the leaks, I first switched off the pulsed mode and within a few minutes established new "spray transfer" weld parameters. With the spray mode I set the 0.045 wire feed rate higher, at "400 ipm". With the higher spray wire feed rate I increased the actual weld production by 25%and the leak test for the new spray transfer welds was "zero percent".

AS THE WELD TRAVEL RATE AND WIRE STICK OUT WAS CONSTANT, THIS WAS A GREAT APPLICATION TO COMPARE THE MILLER PULSED MODE WITH SPRAY TRANSFER. To reevaluate the pulsed mode at the same wire feed rate set with the the spray weld, I then reset the Miller Invision power source back to the pulsed mode and set the pulsed wire feed rate at 400 ipm. I then fine tuned the pulsed parameters to minimize spatter with the shortest optimum arc length. The new pulsed welds looked as good as the spray welds, however when the parts were leak tested approx. 8% of the pulsed MIG welds required weld rework. I turned the pulsed mode off and from 2005 and these important auto / truck part welds are made the old fashioned Ed Craig way, using "spray transfer".

As much as weld equipment companies benefit from making their weld equipment complex and costly, please note MIG welding has never been rocket science. The wires in your $10 Chinese toaster provide the correct amount of resistance and current to maintain the wire in a consistent red heat condition.

As the photo on the right indicates, for a few hundred dollars, you can put two car batteries together. With the 24 volts hooked up a small spool wire feeder gun you can then produce an excellent MIG weld.

In the simple task of melting the tip of a small diameter, MIG wire, weld equipment manufactures today don't blink as they offer a sophisticated, electronic pulsed MIG power source at the cost of a small car. If you have more money than sense you know you need pulsed MIG equipment for you steel welds.

Miller Pulsed MIG Update 2008. It's the same stainless coupling company I visited in 2004, only this time we compare the Miller Axcess pulsed mode against lower cost CV equipment and the traditional spray transfer mode.

In 2004 when this auto parts supplier had problem with the Miller Invision pulsed MIG flange welds on the stainless couplings, I found that we could get the consistent weld results the company desired by switching the pulsed mode off and welding the the flange stainless welds with spray transfer. (See above story).

In 2008 Miller delivered it's new Miller Axcess with a promise that the pulsed mode was now stable and would achieve the desired weld quality on the automated stainless coupling welds. The coupling company was dubious about Miller's promises so they invited me back to compare the Miller Axcess pulsed mode against the traditional spray mode I had previously established.

IT'S LOGICAL FOR ANY WELD SHOP TO ASK, WHAT REAL WORLD WELD BENEFITS ARE DERIVED FROM MAKING THE MIG WELD EQUIPMENT MORE COSTLY AND COMPLEX?

WHAT DOES THE PULSED MIG EQUIPMENT HAVE TO DO TO MAKE THAT COMMON 1/4 (6 mm) FILLET WELD? As the pulsed MIG weld wire travels into the weld at typical speeds of 100 to 700 ipm, that highly sensitive, artificial intelligent pulsed MIG power source has to;

[a] Control and diagnose both the pulsed arc start and arc end weld parameters. If the preset pulsed data does not produce the weld start or the weld end crater will your weld personnel know how to set the correct pulsed data?

[b] Control and diagnose the pulsed low back ground current. If the weld is unstable or lacks weld energy, does your weld decision maker know what the optimum pulsed back ground current should be, or what an adjustment to the back ground current will do to the arc or weld?

[c] Control and diagnose the pulsed high peak weld current. Does your weld decision maker know what the optimum pulsed peak would be, or what an adjustment to the peak current will do to the arc or welds?

[d] Control and diagnose the pulsed frequency. Does your weld decision maker know what the optimum pulsed frequency should be, or what an adjustment to the pulsed frequency will do to the welds?

[e] Control and diagnose the pulsed pulsed up-slope / down slope and the pulsed profile. Does your weld decision maker know what an adjustment to the pulsed profile, (select one of 4 million available wave forms) will do to the welds?

FOR DECADES SPRAY TRANSFER HAS BEEN A SIMPLE PROCESS, YET FEW WELD SHOPS PROVIDED THE PROCESS TRAINING NECESSARY TO ATTAIN PROCESS OPTIMIZATION.. IN CONTRAST TO THE COMPLEXITIES ASSOCIATED WITH PULSED MIG, LOOK HOW SIMPLE IT IS TO MAKE THAT COMMON STEEL FILLET WELD FOR ANY STEEL OR STAINLESS APPLICATION, USING A CV POWER SOURCE, AN ARGON CO2 MIX AND 0.045 (1.2 mm) WIRE:

[1] You select one of three optimum wire feed positions, (from my weld books and training resources).

[2] You set the optimum spray weld voltage, one of two settings (from my weld books and training resources) then fine tune the voltage by the sound or spatter length and shape.

 

If the weld shop was confused about
the two control short circuit and spray modes.

what hope does the shop have understanding pulsed
MIG if pulsed parameter adjustments are required?

 

A traditional CV, MIG power source may be short on electronics, however it does a great job while welding as it automatically maintains the arc length during wire stick out variations.

The low cost, durable MIG equipment provides three unique MIG weld transfer modes suited to all metals. Short circuit provides controlled low heat input suited from 20 gage to 0.100. Controlled globular produces a small amount of weld spatter and suited to weld 14 gage to 0.125 and depending of the use of robot or manual welding, spray is suited to welding all steel parts >0.070.

 

WHAT ABOUT THOSE INVERTERS OR CC/CV MULTI-PROCESS POWER SOURCES?.....Did you know the regular lowest cost CV power source is superior to an Inverter and a multi-process or pulsed power source when used for the MIG weld modes, short circuit or spray and for welding with the gas shielded flux cored wires?. (This info is not available from Miller, ESAB or Lincoln, however the evidence is available in my MIG and flux cored Process Control training CDs.

There is a great value for any weld decision maker, when they combine weld process expertise with a $2000 - $3000 CV power source and a simple two part gas mix that can handle the vast majority of the world's welding applications.

Ed providing MIG and flux cored process control training
to 60 engineers and managers from 6 countries.

2010: MIG WELD BEST PRACTICES AND PROCESS CONTROL TRAINING FOR WELD OPTIMIZATION. MOST COMMUNITY COLLEGES DON'T PROVIDE IT, UNIVERSITIES THAT OFFER WELD ENGINEER DEGREES DON'T DO IT, COMMUNITY COLLEGES THAT TEACH WELDING RARELY DO IT, AND WELD SHOPS GIVE IT MINIMAL CONSIDERATION .

IF THE WELD PROCESS CONTROL TRAINING IS PROVIDED FROM MY CD, MIG AND FCAW POWER POINT PROGRAMS, THE WELD RESULTS FOR YOUR ORGANIZATION CAN BE REMARKABLE.

[a] WELD PERSONNEL WILL NO LONGER HAVE TO "PLAY AROUND WITH WELD CONTROLS" TO ATTAIN OPTIMUM WELD DATA.

[b] WELD PERSONNEL WILL KNOW WHEN TO SWITCH FROM SHORT CIRC, GLOBULAR SPRAY OR PULSED OR WHEN TO CHANGE THAT WELD WIRE SIZE OR GAS MIX FOR OPTIMUM WELD QUALITY AND PRODUCTIVITY.

[c] WELD PERSONNEL WILL IMMEDIATELY UNDERSTAND THE ROOT CAUSE OF THEIR WELD ISSUES AND WILL PROVIDE INSTANT WELD PROCESS RESOLUTIONS NECESSARY FOR THE COMMON ALL WELD ISSUES.

[d] WELD PERSONNEL WILL UNDERSTAND THE RELATIONSHIP BETWEEN WELD COSTS, WIRE FEED SETTINGS AND THE WELD DEPOSITION RATES THEY DAILY ATTAIN.

A FEW OF ED'S WELD PROCESS OPTIMIZATION PROJECTS, FORD F 150 FRAMES - VOLVO CABS - CORVETTE FRAMES- HARLEY FRAMES - NEW BEETLE SEATS AND ED ALSO ESTABLISHED THE ROBOT WELDS FOR THE WORLD'S LARGEST CATERPILLAR TRUCK.

click here for Ed's best practices / process control materials.

ARE YOUR PEOPLE WELD
PROCESS QUALIFIED?

Why not give the personell who make weld decisions this
FUNDAMENTAL MIG WELD PROCESS CONTROL TEST

HOW FAR IN THE WELDING INDUSTRY DID WE EVOLVE BETWEEN 1988 AND 2008? In the graphs below we have two MIG welds both set with optimum weld data. If you believe in the importance of MIG arc stability take your choice. Compare the spray voltage (red) and current (black) graph on right from a regular $2000 MIG power source built in 1988, with the optimum pulsed mode graph on the left from a $12.000 USA manufactured pulsed power source built in 2008.

Even lawyers could figure this weld equipment performance graph out.

 

In one weld process control presentation I provided a process control work shop with a large group of ASTEC / Kolberg managers and engineers. There was two lawyers present, ready to give a talk on patents. I asked the lawyers which of these graphs they would accept in the attainment of consistent, optimum MIG weld quality. You know they both picked the one on the right.

The next two pictures are are two 3/16 (4.8 mm) fillet welds I made during 2003 on 1/4 stainless steel. The welds were made with a Lincoln 300 Power MIG. The 300 power source was a single phase, pulsed MIG unit that retailed at that time for approx. $3,700. This pulsed MIG power source has pre-scheduled pulsed programs for specific wire types and diameters.

This Lincoln pulsed MIG power source was purchased by a company that welds both steel and stainless parts. Due to it's daily welding issues, (most caused by lack of process expertise) this company believed it needed Lincoln's so called unique pulsed power source. The MIG wires used for the 3/16 fillet welds were 0.035, (1mm) - 308L and 309 wires.

With the Lincoln power source, I set the 0.035 wire feed at 550 ipm, a setting that should have been an optimum pulsed wire feed rate. The power source provided the pulsed parameters, I simply had to set the trim, (fine tune the weld voltage) to attain the optimum pulsed arc length. The manual welds were untouched after welding. Take note of the mediocre pulsed weld appearance and also the heat affected zone in contrast to the spray photo.

Th following pulsed MIG picture is worth a thousand words. Provide a macro
examination of your pulsed MIG weld fusion and then compare with spray transfer.

$3700: Lincoln 300. Pulsed MIG "On".

Lincoln 300: Same wire feed settings as above
with the pulsed mode turned "off".

With the pulsed mode switched off, the Lincoln 300 power source was set to spray transfer. The same weld wire and wire feed rate as the pulsed weld were used for the 3/16 stainless spray transfer fillet weld. As you can see above, even the spray weld was poor with an obvious lack of weld energy. Poor slope output for spray is common from pulsed MIG equipment. As you can see when comparing both welds even the HAZ is similar. My point is simple. Why pay extra for the pulsed electronics when you don't need them? Why pay for something that provides inferior performance to traditional CV equipment and is less durable and more costly to repair?

Check the weld similarity from the two weld transfer modes.
Check out the Lincoln poor performance for both the pulsed and spray weld.

The above welds would be dramatically improved using the same wire feed settings and spray transfer from a regular > 250 amp CV power source. So we have another weld shop that purchased a pulsed product that did not live up to the salesman promises.

 

IF YOU WANT TO FIND THE WORLDS WORST WELDS
PAY A VISIT TO AN AUTO / TRUCK PLANT

NO WELD EQUIPMENT ISSUES HERE,
JUST LACK OF ROBOT WELD PROCESS EXPERTISE.

 

 

2003 - 2004. Weld Equipment. Lincoln Pulsed Power Wave purchased by managers
and engineers who lacked the ability to take ownership of a aimple welding process.

These Ford truck robot MIG welds were managed and programmed by engineers with degrees and robot weld personnel who thanks to their inexperienced management were not given the training required to establish Best MIG Weld Practices and Robot Weld Process Controls.

Purchase the most expensive and most sophisticated electronic
MIG equipment available. Make some bad choices on the weld wire size selected. Mix in inexperienced, hands off weld management. Toss in some poorly trained engineers, supervisors and technicians and you to will have the right combination to produce truck frame welds that look like they fell out of the rear end of a pigeon as it flew over the parts.

What a combination, America's most expensive pulsed power source welding on America's most expensive truck, it was a lousy marriage. Here in the USA we can blame the loss of many jobs on overseas lower labor costs or superior Japanese quality, which from a weld perspective is simply a myth. If we face weld reality, we may want blame a good portion of the demise of the Big Three and North American job losses on under qualified, manufacturing management who for decades lacked the ability to control and optimize the equipment they own and therfore lacked the abilty to recognize the process control training necessary for their plant employees.

 

Remember optimum MIG welds with the best possible weld fusion are not about a unique weld transfer mode such as pulsed, and so called unique wave forms, they are about a balance between the stable weld energy (slope output) delivered and the weld deposition rates and travel speeds provided.

 

Visit Ed's Weld Process Control Training Resources.

THE FOLLOWING IS A CASE OF WELD PRODUCT MARKETING / SALESMANSHIP AND BOVINE FECAL MATTER THAT FROM MY PERSPECTIVE IN HAS REACHED AN ALL TIME LOW.

I was amazed to read one advertisement in the Nov. 2003. Weld Journal, a magazine that often struggles to walk a line between it's source of advertising revenue and maintaining unbiased weld technology credibility.

The advertisement in the Weld Journal was from National Standard, (NS), a primary North American MIG wire manufacturer. The NS advert made ridiculous claims for it's new Pulse PLUS Steel MIG Weld Wire.

National Standard claimed. "That with their unique MIG wire and the pulsed MIG process you will get less weld spatter, less weld fumes and their MIG wire will reduce the need for grinding. NS also claimed that their pulsed wire is supposed to provide a wider operating range than competitive MIG wires. NS made four claims that were simply four lies.

BS from NS with it's so called Pulsed MIG Plus MIG Wire.

When an industry MIG wire leader like National Standard has to rely on marketing BS you know there will always be a salesman ready to deliver it. A sad point also is the Weld Journal printed the above add.

SHAME on National Standard, a major North American weld wire manufacturer for it's gross product lies and complete lack of respect for the intelligence of it's North American welding customers.

SHAME on a Welding Journal affiliated with the none profit American Weld Society for providing this ad. This is a journal that prides itself on it's technical articles, perhaps this journal forgot that it only benefits it's "paid subscribers" as long as the information and advertising it provides is credible.

SHAME ON the welding industry that's been using the MIG process for more than five decades, an industry which still has many gullible readers that actually believed the NS claims and purchased this ridiculous MIG wire.

Hello Ed. We are trying to utilize GMAW-P on an HY-80 steel pipe welds. I was pushing for gas shielded flux cored wires, but our engineers will not allow flux cored wires for our procedures. The engineers complain of poor mechanical properties from the flux cored wires on the HY metal. We can't use spray as many of the welds are out of position. We are having a difficult time passing UT with our Miller Invision pulsed power source. The MIG pulsed parameters required provide a wide arc zone and long arc length, this results in inconsistent weld fusion.

We are thinking about switching to Lincoln Pulsed equipment, as they tell us with their equipment that we can control the pulsed wave forms and get better results. The Miller Equipment does not allow wave form manipulation from the interface, you have to run off the factory resets. Do you have any suggestions on getting better results with our GMAW-P equipment?


Ed's Reply: Forget that nonsense about "pulling a magic wave form out of that red machine". Your question brings to light some of the pulsed process issues I have been talking about for more than a decade. Pulsed variable parameters and pulsed arc length sensitivity combined with a lower energy, fluctuating pulsed MIG arc plasma will have welding consequences especially to those who are concerned about the weld fusion attained. Of course to attain more weld energy with pulse one can always increase the pulse parameters. However there are limits and when those parameters are outside the optimum pulsed parameter range, you will not likely be pleased with the resulting welds.

Good luck with the Lincoln Power Wave and it's numerous wave forms. I think you will find that wave form control which sounds great in the Lincoln marketing brochure is going to have have little impact on your weld applications. You may want to read one of my many experiences with the Lincoln Power Wave when it created serious weld quality issues for American Axle, a major tier one axle manufacturer. Check out the MIG equipment section.

Your statement on the engineers comments on unacceptable gas shielded flux cored weld mechanical properties shows a real problem in your organization and a common major problem for many companies.

If your company is interested in attaining consistent weld fusion and higher than traditional weld strength it should fire the engineers who made the ridiculous flux cored statement and quickly get used to welding with the highly cost effective gas shielded flux cored consumables or better still take a look at TIP TIG.

Your companies weld issues are typical of many companies in the pipe and pressure vessel industries, companies where you will find many engineers who provide MIG and flux cored weld opinions, yet few are qualified to make a rational MIG or flux cored weld process decision.

Ed's answer. You are finding the weld reality that the pulsed equipment you purchased does not live up to the promises made by the equipment mfg. Call me reference the solution to this problem. Ed.



ROBOTS AND HIGH SPEED PULSED MIG WELD CONCERNS: The pulsed, inconsistent, lower open arc energy attained from < 2005 pulsed equipment was not the logical choice for many high weld speed robot applications, especially when you consider the two prime weld quality issues on many robot welds on steel or stainless parts > 4mm was;

[1] marginal or lack of side wall weld fusion.
[2] inconsistent or skipped welds caused by inconsistent transfer of the electrons across the arc.

SPRAY VERSUS PULSED PLASMA AND THE WELD STREAM:
In contrast to the ever changing, peak to back ground pulsed MIG transfer mode, the constant energy, higher velocity, denser plasma with the spray transfer weld stream, offers three unique weld attributes;

[1] Spray Transfer: With consistent weld parameters, spray transfer will provide a less fluctuating, more consistent plasma shape and therefore maintain the location of the arc plasma energy influencing the weld fusion potential. In contrast to spray, the pulsed plasma is typically weaker as 50% of it's time its at the back ground current setting. In the pulsed back ground to peak condition, the plasma profile continuously collapses between a narrow and wider plasma.

[2] Spray transfer can weld with a much shorter arc length than pulsed. The shorter arc length focuses the most concentrated area of the arc plasma plasma energy in the weld rather than over the external weld surface. The concentrated, higher energy spray plasma is beneficial to attaining optimum weld fusion and stable electron transfer with high speed welds.

[3] The traditional spray transfer plasma configuration and short arc length potential can provide an arc less sensitive to mill scale or specific coatings.

THE WONDER OF THE REGULAR MIG ARC: When you read anout the pulsed MIG electronics performing miracles as the MIG arc lengths change, remember In most robot and automated welding systems, the MIG arc length (wire tip to work distance) variations that take place during the welds should be minuscule. However if the constant voltage (CV) arc length does change during the weld, the traditional CV MIG power source has always had that unique slope feature in which a small voltage change in the arc will result in a high rapid weld current change that instantly "self corrects the arc length".


E-mail from l. KD - P&F. 12 /07

Dont forget the influence of the spray weld gas
ON THE STABiITY OF SPRAY TRANSFER WELDS.

 

Click here for Ed's MIG Gas Mixes

GAS MIXES CAN PROVIDE A GREAT CONTRIBUTION TO WELD STABILITY & WELD ENERGY In a time of equipment electronic bells and whistles, please remember with MIG gas mixes, that the CO2 gas dissociation and oxidation properties, are often not given the credit or consideration they deserve. Ed introduced 4 important gas mixes in North America and recommends you visit the MIG gas section of this site.

The Japanese will often add electronics to MIG welding equipment without understanding why they added the electronics

 

 

E-mail. Oct 2008:

I am emailing you because I have come to a questionable snag with my pulsed MIG equipment. I have the equipment set in the spray mode. I am welding on 5/16” carbon steel material, my settings are set to spray transfer (29 volts 500 wire speed in/min).

When making a 3/16” fillet weld with the 0.035 wire I have noticed that at the end of the weld, the weld flattens out and has what I have been taught to refer to as a “fish eye” ( I am not sure if this is the right term for this problem ).

The attached photo will show you what I am referring to. When coming to the end of my weld I back over the weld about ¼” instead of just stopping. I don’t pull my nozzle away before I let the trigger go, so I don’t think this issue is caused due to the length of the stick out. My gas is set to 35cfh argon/CO2 mix.

Could you please advise what may be causing this poor finish is this just cosmetic or an issue that needs to be addressed? If this is an issue that needs to be addressed could you please explain the proper procedure for fixing. These parts are under extreme vibrations and some stresses Vertical / Horizontal and Lateral. Thank you.T Eason.

Ed's Reply. Two things going on here.
[1] First the weld picture indicates poor side wall fusion. As you are using good spray parameters the lack of fusion is likely a result that the weld surface was wire brushed, however the mill scale has been left. If you are concerned about fatique properties you don't MIG weld over mill scale. Grind the weld area before welding, I am sure you will see a difference in the weld appearence.

[2] A fish eye is typically a pore evident in a failed weld and the bright shiny appearence in the pore indicates the presence of hydrogen, so you dont have a fish eye. You do have a pulsed power source that has a built in defect. This is a a commom classic issue with pulsed equipment in which the machine controlled end parameters or burn back parameters are set too high, (more evidence that pulsed equipment manufactures don't correctly test the equipment they build.) I see this defect all the time in pulsed equipment in robot cells. At the end of the weld, the high voltage spike applied for the burn back causes a suck back effect in the arc leaving that classic hole in the crater. In many instances if you examine with magnification you will find shrinkage cracks around that hole and with your fatigue concerns, this defect has to be ground out and the crater filled in. My MIG process control training resources deal with this issue and provide process solutions, however you would be well served to send the power source back to the company who manufactured it. It's ironic that this defect would not occur on a lower cost traditional CV power source.




THE PULSED MIG PROCESS HAS MORE THAN ONE ACHILLES HEEL: Even with the world's best pulsed equipment, on many common applications the Pulsed MIG process will always have its Achilles Heel. Visit section 2 of pulsed MIG. Find out about useless wave form options and concerns for lack of weld fusion.

Invest in your weld career, its your choice talk to a salesman or order Ed's books and MIG and flux cored, manual or robot weld process control CD training resources.

IF WELD QUALITY IS YOUR FIRST CRITERIA, PULSED MIG WILL NEVER COMPETE WITH TIP TIG

Pulsed Section 2. [] Take a look at the Panasonic Ripple Farce. [] This tractor mfg paid extra when they took their advice from a weld salesman. [] The Miller pulsed MIG equipment fiasco. [] Lincoln Power Wave caused Ford Truck axle cracks, [] Was this Airco MIG equipment junk?. Continue with extensive pulsed MIG welding data your MIG equipment manufacturer forgot to tell you, Section 2.

For MIG and Flux Cored process expertise visit www.weldreality.com