MIG Welding Gauge Steels and Alloy Steel Part1

5/27/2018 MIG Welding Gauge Steels and Alloy Steel Part1

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MIG Welding gauge steels and alloy steel parts < 1/8 (< 4 mm).

The bove actually happened because the plant management and engineersresponsible for the bomb lug welds did not understand or take ownership ofthe MIG weld process and equipment used in their plant.

HAVE YOU SEEN THE WORLD'S BEST WELD PROCESS TIP TIG? www.tiptigusa.com.
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THIS UNIQUE WELD PROCESS PROVIDES LESS WELD HEAT AND BETTER WELDQUALITY THAN ANY TIG OR MIG WELD AND PROVIDES THO WELDS AT A THIRD OFNORMAL TIG WELD COSTS.

Welcome to MIG Short Circuit welding and Pulsed MIG onCARBON STEELS AND STAINLESS GAGE APPLICATIONS.

As the pulsed MIG process painfully evolved over the last few decades, the utilization ofshort circuit decreased for gauge, carbon steel applications. The weld reality is that incontrast to pulsed MIG, the lower cost traditional CV MIG equipment that provides shortcircuit welding can offer many unique superior weld attributes for most thin gaugesteels and alloy steels none code weld applications.

Note: This site has been a weld blog long before the word blog was discovered. Thissite cuts out the salesmanship from an industry that depends on sales advice anindustry that has too many weld decision makers that have to play around with 50 yearold simple weld controls.

This site brings the weld process contol expertise I gained over 40 years and this sitebrings the opinions of other weld personnel that also strive to see this industry gain therespect it deserves.


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During short circuit weldtransfer, unlike the open arcpulsed, globular or spraytransfer modes, the uniqueshort circuit arc spends 50% ofit's time in the "arc off"

condition.

When the electrode positiveshort circuit weld wire makescontact with the negativegrounded part it's in the arc offcondition. This cold conditionis controlled by the powersource slope. With the shortcircuit, the resistance to thecurrent is lowered, the weldvoltage drops and the current

rises to the slopes limit. The short circuit current rise is sufficient to melt the wire tip

and form an arc which results in the formation of a fluid droplet that quickly develops onthe MIG wire tip.

As the short circuit wire feed is constant, the weld dropletbeing formed is driven to the weld and also drawn bycapillary action into the surface of the weld. The shortcircuit weld droplet is detached and the wire is driven tothe weld to repeat the arc off, arc on cycle which typicallyoccurs 60 to 120 times per-second.

Note: With argon gas mixes, the argon mix gas plasma (asindicated in the video below) partially covers the fluid

droplet during it's formation. In contrast, when usingstraight CO2, the CO2 plasma would be at the bottom of the weld droplet, supporting thedrop and disturbing the drop till it gets larger and then transfers in an erratic manner.

A UNIQUE ATTRIBUTE OF SHORT CIRCUIT TRANSFER WELDING: The short circuitmode is the only weld metal transfer in which the arc goes on - off. The "arc on - off"weld attribute is a logical weld benefit on thin gauge, or applications which require agap has to be bridged.

If welding stainless and steel thin gauge applications, short circuit is an excellent weldtransfer mode, however stainless produces more sluggish welds than carbon steelwelds. The sluggish welds welds are especially noted on stainless parts > 0.080. If youwant gage welds with minimum distortion, minimum spatter and minimum cleaning,watch what TIP TIG www.tiptigusa.com can do for thin stainless in the following video.

REGULAR TIG VERSUSTIP TIG ON THIN GAGE APPLICATIONS:
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REGULAR TIG: YOU CAN USE REGULARTIG, TAKE TOO MUCH TIME, PUT IN TOOMUCH WELD HEAT AND MAKE WELDSLIKE THIS. PLAY THIS VIDEO FIRST

TIP TIG: YOU COULD GET ON WITH YOUR LIFE,REDUCE YOUR WELD COSTS. MAKE HIGHQUALITY TIP TIG WELDS LIKE THIS WITH MUCHLESS HEAT INPUT.

REGULAR TIG: Play this video first:Regular TIG typical manual weld speeds forthese welds is 4 to 7 inch/min.

The TIG arc on time for this 12 inch weldwould be around 2- 3 minutes. Take a look

at the irregular weld quality influenced bytoo many arc start / stops, and take specialnote of the large heat affected zone that'sgoing to create distortion concerns.

Someone can always do a better TIG weldthan this but it will never match the qualityand productivity attained with TIP TIG.

TIP TIG: Manual TIP TIG weld travel rate48 inch/ min as noted on the UTube secondcounter with this 12 inch length of 3 mm weldmade with an arc on time of 15 seconds:

Note the uniform weld quality that comes from theconstant wire feed rate and only one arc start /stop. Examine the smooth clean, unoxidized weldsurface, the very small HAZ and lack of welddistortion and weld minimal fumes. Think aboutthe savings that will results from less cleaning.

From welding small, long track, 3 mm fillet weldson the deck of an Aircraft Carrier to the small sizestainless welds typically found on food andbeverage / processing equipment, no other weldprocess can provide long, small size gage weldswith the TIP TIG quality and the lowest possibleweld heat input.

On robot stainless gauge applications > 0.070, thanks to the increased weld speedpotential, low spray parameters and an 0.035 wire can be used. Pulsed MIG with 0.045wire is also applicable but not necessary when manual welding > 16 gauge stainless


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parts.

A Short Circuit and Pulsed Transfer WeldConsideration.Short circuit welding transfer available from a lowcost, constant voltage, (CV) traditional MIG power

source with an 0.035 (1mm) wire is suited for allmanual steel applications from 20 to 12 gauge.

Note: A benefit of the pulsed mode for some > 16 gauge applications is the lower cost,easier to feed, 0.045 (1.2 mm) carbon steel or stainless wire may be used instead of the0.035 (1 mm) wire. 045 wire provides a little more deposition which may be beneficialwhen larger welds are required on specific thin parts. As a lower cost weld equipmentalternative you could take regular, much lower cost CV MIG equipment and set that0.045 in the globular mode and achive the same deposition as the pulsed MIG..

Designers and manufacturing engineers and managers of gage applications often sufferfrom a lack of MIG weld process knowledge and that can lead to dramatic weld costconsequences.

When welding thin, carbon steel or stainless robot welded parts < 2mm you may find;

[a] unacceptable part part tolerances,[b] unacceptable weld gaps,

[c] poor part fixtures,[d] inappropriate weld joint designs,[e] poor consumable wire size selection and weld equipment with poor performance,[f] poor weld parameters and poor technique.

Of course items A to F will lead to weld rework and weld cost ramification. Commonissues are weld burn through, distortion, spatter leading tp weld rejects and extensiveor rework. To add to the thin gauge weld issues, it's a sad fact that the majority manyautomotive and truck manufacturing plants that use MIG welding robots, lack the


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engineering ability to select the correct size MIG wire or the optimum weld transfermode for the application.

ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES. A FEW OF HIS PROJECTS,FORD F 150 FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES- HARLEY BIKE FRAMES -NEW BEETLE CAR SEATS AND THE ROBOT WELDS ON THE WORLD'S LARGESTCATERPILLARTRUCK.

Ed's unique manual and robotMIG Process Control Training Programs

STEEL GUAGE CHART, OPTIMU WIRE SIZE & WELDING GAS MIXTURE.
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Gauge to inch conversion

GAUGE 3 = 0.239 inch O.6 cmGAUGE 4 = 0.224 inch 0.56 cm

CONSIDER 0.045 (1.2 mm) WIRE. ARGON-10-15 C02 FOR THESE MANUAL / ROBOT SPRAY

/ PULSED WELDS.

GAUGE 5 = 0.209 inch 0.53 cmGAUGE 6 = 0.194 inch 0.49 cm

CONSIDER 0.035 (1 mm) WIRE.ARGON-10-15% C02 FOR MANUAL / ROBOTSPRAY. IF USING PULSED USEDAN 0.045 WIRE WITH THE SAME GAS MIXES.


CONSIDER 0.035 (1 mm) WIRE. ARGON 5-10%

C02 OR ARGON 2 TO 5% OXYGEN FOR THISMANUAL / ROBOT SPRAY WELD . IF USINGPULSED USED AN 0.045 WIRE WITH THESAME GAS MIXES


CONSIDER 0.035 1 mm WIRE.

ARGON 5-10% C02 OR 2 TO 5% OXYGEN FORTHIS MANUAL / ROBOT SPRAY WELD. IFUSING PULSED USED AN 0.045 WIRE WITHTHE SAME GAS MIXES,


CONSIDER 0.035 1 mm WIRE ARGON 15-20%C02 FOR THIS MANUAL SHORT CIRCUITGAUGE. THIS CAN ALSO BE SPRAY ORPULSED SPRAY WELDED WITH A ROBOTUSING THE 035 WIRE AND 5 -10% CO2 OR 2-5OXYGEN. IF USING PULSED USE AN 045WIRE WITH 5 TO 10 CO2.


CONSIDER 0.035 1 mm WIRE.ARGON 15-20% C02 FOR THIS MANUAL

SHORT CIRCUIT GAUGE. THIS CAN ALSO BESPRAY WELDED WITH A ROBOT USING 5 -10% CO2 OR 2-5 OXYGEN. IF USING PULSEDUSED AND 0.045 WIRE WITH THE SAME GASMIXES


CONSIDER O.035 (1 mm) WIRE ARGON 5- 10%C02 FOR THIS SHORT CIRCUIT GAUGE. IFUSING PULSED USE AN 045 WIRE AND 10

CO2.


CONSIDER 0.035 1 mm WIRE.ARGON 5-10% C02 FOR THIS SHORT CIRCUITGAUGE. IF USING PULSED USE AN 0.045

WIRE WITH THE SAME GAS MIXES

GAUGE 19 = 0.042 inch 0.11 cm

GAUGE 20 = 0.035 inch 0.08 cm

CONSIDER 0.035 1 mm WIRE ARGON 5 TO 10CO2 / ARGON 2% Oxy FOR THIS SHORTCIRCUIT GAUGE. USING PULSED USE AN 045

GAUGE 21 = 0.033 inch 0.08 cm

GAUGE 22 = 0.03 inch 0.07 cm

CONSIDER 0.030 0.8 mm WIRE ARGON 5%OXYGEN FOR THIS SHORT CIRCUIT. USINGPULSED? USE AN 035 WIRE WITH THE SAMEARGON OXY MIX GAUGE


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WIRE AND LOW ENERGY ARGON 5 TO 10CO2.GAUGE 23 = 0.027 inch 0.06 cmGAUGE 24 = 0.024 inch 0.06 cm

CONSIDER 0.030 (0.8 mm) WIRE ARGON 5%OXYGEN FOR THIS SHORT CIRCUIT GAUGE,BE CONCERNED ABOUT WIRE FEED ISSUESWITH 030. USING PULSED? USE AN 0.035WIRE WITH THE SAME ARGON OXY MIX...

WELDING STAINLESS STEEL ? USE THESAME RECOMMENDATIONS WITH ARGON 2-5% CO2. ALSO CONSIDERTIP TIG

E-mail. Weld Question, 06 /20/03

Hi Ed, I would like to know what the critical factors are that determineshorty circuit weld fusion. I often wonder if short circuit transfer simplywon't put heat into the base metal fast enough to achieve fusion onanything greater than gauge thickness. Right now I have a single phase,Miller 185 amp power source. We weld steel and silicon bronze base metalfor architectural work, balconies, railings, etc. Typically we are joining 1/2to 3/4 inch square tubes to 1/2 x 1 to 1/2 x 2 with single and double bevel

prep. I find I must run in globular mode with the 0.035 wire we use. I don't think the

Miller 185 will get me into spray transfer and am trying to decide if a machine in the 250amp class is the solution. We are currently stuck with single phase power What is yourtake on all this?

Regards, Erik Lander.

The scourge of the weld industry.
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If every MIG weld in North America was sectionedtomorrow, the majority would reveal lack of fusion.

Ed's reply. Erik, with manual short circuit transfer, depending on the steel

application you should be concerned about fillet weld fusion oncomponents over 0.100 and consider pulsed, controlled globular or lowspray settings for these applications.

Using argon 10 to 20% CO2, an 0.035 (1 mm) steel wire will require >200amps to attain optimum spray transfer, that's why the CV. "250 amp" power

source is a popular equipment choice for sheet metal shops. With your low currentpower source, you could get a lower spray transition current if you used argon oxygenoxy mix (try 2% oxy or 5%CO2). With argon oxy mixes you will get into spray around 180amps, however, note these argon oxy gas mixes are not suited for short circuit transfer.If you really want to get into spray with argon CO2 mixes on your power source, youwould have to use an 0.030 (0.8mm) MIG wire, however I would not recommend that asyou could then expect wire feed issues with this small wire.

A logical solution with your power source when welding carbon steel welds, giveconsiderations to an 0.035, E71T-1, gas shielded flux cored wire with argon - 25 % CO2.With these consumables and your small power source you could weld any metalthickness in any position. Good luck Ed.


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ROBOT AND MANUAL MIG DATA DIFFER:

MIG welding data recommendations can change dramatically whenchanging from manual to automated welds. In contrast to manual welding,when welding thin gauge applications with robots, the welds typically canbe made with "higher weld travel speeds" which allows higher weld currentsettings or different weld transfer mode options.

Pulsed spray transfer " allows robot welds to be made on carbon steel oralloy steels in the thickness range of 0.045 (1.2 mm) to any thickness.

Robot welds using 0.035 (1mm) wire with regular "spray transfer" set at low weldingspray parameters can be used on parts as thin as >0.070, >1.8mm. No weld gaps andshort weld lengths preferred.

Robot welds with an 0.035 wire with short circiut can weld parts > 1 mm, under 1 mm theweld burn through risks are high,

Globular Benefit: For welding those exhaust components or Harley bike frames that arepoorly put together and end up with weld gaps, an alternative weld transfer mode topulsed and short circuit is the globular transfer mode. For globular weld transfer use0.035 wire typically set at 400 to 600 ipm with a weld voltage range of 20 to 24 volts. Thismode provides low to medium weld energy at higher weld deposition than short circuitand on round parts there will be low weld spatter.

I BELIEVE EVERY MIG WELDING DECISION WILL BENEFITFROMTHESE 3 BOOKS.

[1] MY "MIG AND ROBOT WELD PROCESS CONTROL"BOOK.

[2] MY "MANAGEMENT AND ENGINEERS GUIDE TO MIG"BOOK.

[3] MY "MANUAL MIG & FLUX CORED BOOK".

Note: These books and my MIG self teaching / training video and MIG process controlCD's are found in the training resources section of this site(click here).

My process control training resources, simplify the selection of optimum MIG wire feedand volt settings for all common electrode diameters used on manual and robotapplications. The process controlwelding CD'swill provide your robot personnel andwelders with the ability to instantly set the optimum MIG weld transfer modes and weldparameters for any steel application.
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Two important steps for effective weld process controls.

[1] Avoid weld sales advice.

[2] Take a logical process approach in selecting the optimum MIG wirediameter for your applications.

Lets see. If we have traditional CV MIG equipment, the 0.035 or 0.040(1 - 1.1mm) MIG wire diameters provide a short circuit weld current range that is bestsuited for the common thin 20 - 12 gauge, steel and stainless applications. We shouldavoid using smaller MIG wires as they are not necessary and they can create wire feed

issues.

OVERSIZE MIG WIRES AND POOR CONSUMABLE CHOICES:

For decades many auto / truck managers believed that when it comes towelding"the cheaper bigger MIG weld wires are better and will povide costreductions"

[] The use of oversize MIG wires 0.045 - 0.052 - 0.062 which require too high weld currentfor gage parts is common in the majority of plants.

[] The use of self shielded flux cored wires is also common. Take note; These weld wireshave no place in any plant in which desires consistent optimum weld quality.

[] While the majority of plants that use argon mixes utilize the E70S-6 wires. The weldreality is that the E70S-3 wires would have less oxides islands on the surface, lessporosity and less undercut potential. Reducing oxides is important when welds are tobe painted or coated.

To attain optimum weld transfer from the over sized diameter MIG wires requires highweld current and typically the current required will not be compatible with the gaugesize welded. The bottom line is the auto industry needs managers who understand theimportance of weld consumable selection, weld process controls and best weldpractices.

My process control trainingprogramssimplify and teach the best practices - processcontrol requirements and anyone who can read English can present these programs.

SELF SHIELDED FLUX CORED WIRES ARE THE WORLD'S WORST WELD WIRES YETTHEYARE A COMMON CONSUMABLE CHOICE FOR MANY IN THE AUTO / TRUCK INDUSTRY.
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SELF SHIELDED FLUX CORED WIRES AND WELD PROCESS IGNORANCEBY CHRYSLER, CAUSED MILLIONS IN UNNECESSARY WELD COSTS:

2006: WHEN I SEE SELF SHIELDED FLUX CORED WIRES USED IN ROBOT CELLS OR INANY INDOOR WELD APPLICATION, APART FROM WANTING TO THROW UP AND HOLDMY NOSE TO AVOID THE AFFECTS OF THOSE OBNOXIOUS WELD FUMES, I KNOWTHE PLANT SUFFERS FROM THAT INFAMEOUS GLOBAL WELD DISEASE CALLED"managementprocess - ignoranceitis.

AT THE TIME I WROTE THIS BOTH CHRYSLER AND GM MANAGEMENT AREREQUESTING USE OF THESE WELD WIRES FOR THEIR GALVANEALED PARTS WHICHIS IRONIC AS THESE WIRES OFFER NO BENEFITS FOR GALVANEALED ORGALVANIZED. THANKS TO THE WELD ISSUES THE USELESS SELF SHIELDED WIRESGENERATE, THESE FLUX CORED CONSUMABLES EACH YEAR WILL COSTCORPORATIONS MILLIONS OF DOLLARS IN LOSS OF ROBOT OR MANUAL WELDPRODUCTIVITY, WELD PART REJECTS, EMPLOYEE TURN OVER FROM THE


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OBNOXIUS WELD FUME ISSUES IN WHICH MORE WORKERS SHOULD BE TAKINGLEGAL ACTIONS AND ALWAYS EXTENSIVE WELD CLEANUP AND WELDREWORK.

MANY PLANTS WILL USE 0.045 (1.2mm) AND 0.052 (1.4mm) MIG WIRES WITH THEIRCV, SHORT CIRCUIT OR GLOBULAR MODES TO ROBOT WELD PARTS LESS THAN0.100.THESE LARGE WIRES ARE THE FREQUENT CAUSE OF WELD BURN THROUGH,

DISTORTION AND WELD REWORK ISSUES.

MANY PLANTS, ESPECIALLY AUTO / TRUCK FRAME PLANTS WILL ROBOT WELDPARTS 1 TO `4 mm AND USE AN 0.052 (1.4 mm) WIRE, YET THE SPRAY CURRENTWITH THESE WIRES IS BETTER SUITED TO WELDING PARTS > 5 mm

AT THE INFAMOUS "QUALITY IS JOB 1" FORDFRAME PLANT IN DETROIT, MIG WELDING THETRUCK FRAMES WAS MORE OF A COMEDY SKITTHAN AN ENGINEERED, CONTROLLEDFUNCTION.

THE FORD PLANT AND IT'S ENGINEERS AND MANAGERSSIMPLY HAD NO UNDERSTANDING OF THEREQUIREMENTS OF ROBOT WELD PROCESS CONTROLSAND THE PLANT CONSTANTLY USED UNDER TRAINEDEMPLOYEES AND OVERSIZED MIG WIRES ON IT'S ROBOTMIG WELDING TRUCK FRAME LINES.

THIS IS HOW FORD IMPLIMENTS "QUALITY IS JOB 1". ATONE OF IT'S PLANTS. YOU WOULD FIND AN EMPLOYEE ATTHE END OF THE ROBOT LINE. HIS JOB WAS TO USE ACHEAP SWEEPING BRUSH, DIP IT IN BUCKET CONTAINING YELLOW PAINT AND TRY

TO MARK THE NUMEROUS BAD WELDS ON EACH FRAME AS THEY PASSED AT THERATE OF ONE A MINUTE. THIS PLANT AND OTHER FORDFACILITIES HAS FOR DECADES HAD THE PROUD ENGINEERINGACHIEVEMENT OF NEVER PRODUCING A ROBOT WELDEDFRAME, WITHOUT MOST WELDS REQUIRING WELD REWORK.

OVERSIZE MIG WIRES WILL NOT ALLOW THE USE OF SPRAYTRANSFER WHICH DID NOT MATTER FOR MANY COMPANIES THAT DID NOT KNOWWHAT SPRAY TRANSFER WAS. OFTEN THE OVERSIZED WELD WIRES END UP BEINGUSED IN THE GLOBULAR TRANSFER MODE. GLOBULAR WELD TRANSFER WAS VERYCOMMON AT FORD, GM, DANA, TOWER AND CHRYSLER PLANTS. THE GLOBULARMIG WELDS WILL TYPICALLY LACK WELD FUSION, CAUSE EXCESS SPATTER ANDCAUSE CONTACT TIP ISSUES RESULTING IN EXCESS WELD REWORK AND ROBOTDOWN TIME.

Weld Wire Facts: Welding carbon steels or stainless steels with an0.035 or 0.045 (0.9 - 1.2 mm) MIG wire, short circuit transfer on mostapplications is found in the weld current range of approx. 80 to 190
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amps.

Optimum short circuit transfer with 0.035 (0.9mm) wires is typically found between 100and 180 amps with a voltage range 15 to 18 weld volts and provides optimum weldresults on parts < 0.100.

On the applications that utilize the 0.035 wires in the optimum short circuit currentrange, pulsed MIG using an 0.045 wire can also be used with similar or slightly higherweld current and deposition rates.

In contrast to the "arc on - arc off", short circuit transfer mode, thepulsed mode is an "open arc" mode that delivers the dropletsacross the arc in a consistent transfer, that is if you havepurchased one of the rare pulsed power sources that actuallyworks in a consistent manner. In contrast to short circuit transfer

set at 150 amps, the OPEN ARC pulsed process set at150 ampswill deliver a weld with greater weld energy.

Note If you were producing manual or robot short circuit welds at 180 amps and youwant to try an 0.045 and the pulsed process, I would start the pulsed weld at 160 amps,then adjust.

Optimum Short Circuit Transfer and Pulsed MIG Wire Diameter Selection for GaugeApplications.

CV Regular MIG Equipment. The best two MIG wire diameters for shortcircuit transferare 0.035 and 0.040 (0.9 and 1.1 mm). In industrial shops, there is

simply no justification for the use of smaller weld wires and if thetypical thickness worked on does not exceed 7 mm there is no

justification for larger wires...

Pulsed MIG The best MIG wire diameter for all carbon steels, stainlessand aluminum gauge applications is the 0.045 (1.2 mm) wire.

THE UNIQUE "0.040" MIG WELD WIRE, THE WIRE THE AUTOMOTIVE

WELD INDUSTRY SHOULD HAVE BEEN USING FOR AT LEAST THREEDECADES:

Using traditional MIG CV equipment: If you could get your hands onthe 0.040 (1.1 mm) wire, it would be the most practical choice for mostrobot and manual MIG short circuit and low current spray carbon andstainless applications in the 1.2 to 7 mm range.

The 0.040 MIG wire would require less current than the 0.045 wire which is especiallybeneficial for the 3 - 7 mm parts and the 040 wire would provide higher deposition and


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better feedability than the 035 wire. The lack of use of this wire should be no surprise ina play around weld industry that rarely implements Best Weld Practices.

NOTE ON ATTAINING 0.040 MIG WIRES: In North America for more than two decades,Lincoln Electric has been in a monopoly position in the sales of MIG wires. Lincoln doesmake small quantities of the 0.040 carbon steel MIG wire, however as Lincoln typically

has had a hard time keeping up with the demand for it's traditional 0.035 - 0.045 steelwire products they are not exited about the sale of 0.040 wire. It's understandable thatfrom their perspective, that without extensive customer demand and without weldprocess educated consumers, there is little incentive for them to market the 0.040wires.

[] The 0.040 wire, optimum short circuit current range is approx. 130 - 190 amps. Thiscurrent range is well suited to short circuit welds on the very common and 14 - 18 gaugecarbon steel and stainless applications. In contrast to the 0.035 wires, with short circuitwelds and the 0.040 wires, you can expect slightly higher weld deposition rates andimproved wire feedability which is very beneficial on robot gauge applications. The0.040 wire needs less current to get into spray than the 0.045 wire making it the weld

wire of choice for 3 to 6 mm spray transfer applications (less undercut and distortionpotential).

[] If you cannot use 0.040 wire, the optimum weld wire for thin gauge current is the 0.035wire which typically uses a working weld current of approx. 100 to 180 amps.

[] The "optimum" short circuit weld current for the 0.045 wire is approx. 170 - 200 amps.In contrast to the 0.035 or 0.040 wires, the 0.045 (1.2 mm) wire operates in a narrow,short circuit wire feed range that delivers higher weld current, thus being less suited tothin gauge parts (


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While we blame China for bad manufacturing pratices, read aboutthis USA Mid West exhaust manufacturer which for years allowedit's welding department to use the wrong welding polarity.

Question: Ed can you describe the difference between straight and reverse polarity inMIG welding?.

Answer: As we can all likely do with some humor in our lives, I thought, rather thananswer this common weld question in the traditional manner, that I would tell you abouta real world welding application I was involved in a few years ago.

A Midwest company that builds exhaust systems for the aftermarket had major MIG weld quality problems. The absent ownerof the company asked if I would visit his plant and report on theplant's welding issues. He told me that some of his customerswere complaining that the carbon steel welded flanges werefalling of the exhausts during delivery to the auto partssuppliers.

I arrived at the exhaust manufacturing plant just before lunch.Like many automotive companies, the plant was too cheap tp

pay $8 an hour for a receptionist. I waited 30 minutes in thelobby and no one answered the phone. To get access to theplant, I walked around to the back door. I entered the plant inthe middle of the busy weld shop and my weld senses went

immediately on high alert. The "MIG weld sounds" I heard from the approx. 40 MIG weldbooths were unique, but I had heard that sound before. I heard a grunt from behind,then again it could have been a pathetic sounding fart. As I slowly turned around I sawwhat could only be called a Englisman's nightmare. Rednecks are not restricted to thesouth and I was within spitting distance of the meanest looking one i had ever seen.


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Thankfully he just grunted and did not ask me to squeal like a pig. What I saw next wasevery weld managers nightmare. Follow this link for the rest of thiswelding story

The bottom line on New Weld Products and"Supply and Demand".

Mostglobalweldshopsbecomeentrenchedwithunhea

lthyculturesandwiththeweldconsu

mables they use daily.

If a new weld product comes alongthat indicates it can provide "real weld weld cost benefits" forthe users, then it's logical that the end users should demand

that product. The fact thatweld shops rarely demand the best and most cost effectiveweld equipment and consumables ia an indication of the levelof the global weld process control and weld cost expertisethat prevails in too many weld shops.

The companies who are typically reluctant to make a majorweld transfer mode or weld consumable changes have oftenused incorrect consumables for years. Eventually these lackof weld management ownership, "play around" with the weldcontrol companies will move the poorly suited consumables

and poor weld practices into their MIG robot cells.
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A frequent weld management solution to robot weld problems.

When they have robot weld quality issues they employ more

manual welders. When they have robot weld productivity issues,

they order more robots.


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Weld Fact: When the unqualifiedmanager or engineers ask theunqualified welders who have skills butminimal weld process expertise, to tryout that new weld wire or gas or powersource, is it any surprise when the

welders don't like the new products?


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modes.

If you use "three part gas mixes" for any carbon steels or anystainless applications, you are not using weld process logic, andtypically you have been getting weld advice from either aninexpericed weld salesman or what we called in England a

shyster.

Let's see, we have another important step for weldprocess control. When it comes to MIG gasselection we don't need to try a different MIG gassix times a year. We don't need the advice of a gassalesman and we should get rid of those costly,useless three part gas mixes. The bottom line is allour steel and stainless MIG welds can be made with a couple ofsimple argon CO2 gas mixes found in the MIG gassectionat this

site. With all the money I am saving, I will be able to afford thatdivorce lawer.

IF PULSED MIG EQUIPMENT WAS NOT AVAILABLE TO GLOBAL WELD SHOPS, ITWOULDHAVE NO IMPACT ON THE INDUSTRIES THAT WELD CARBON STEELS AND

STAINLESS.

WELD QUALITY & PRODUCTIVITY SHOULD NEVER BE AN ISSUE WITH LOW COST, CVMIG EQUIPMENT:
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The weld process mode you select will depend on the weld equipment and consumablesin the shop. With low cost CV MIG equipment, the short circuit, spray or controlledglobular selected can produce, low spatter or spatter free, optimum welds on most steelapplications, that is if the welders have the ability to set optimum MIG weld parameterswithout playing around with the weld parameters.

With a traditional US. MIG power source in $2500 to $3500 range and pulsed MIGequipment in the $6000 to $12,000 range, the wise weld decision maker would placetheir focus on ensuring their weld personnel receive process controltraining,that willenable them to have the ability to fully utilize and optimize the performance of the muchlower cost CV equipment.

"PLAYING AROUND" DOES NOT BELONG WITH BEST WELD PRACTICES ORPROCESS CONTROLS.

2006:For five decades, emphasis in thewelding industry has been on welding skillsrather than on weld process expertise. This isa prime reason why most manual welders still"play around" with their MIG weld controls andthe robots fill up their weld rework baskets.

IN AN INDUSTRY THAT PLACES MINIMALFOCUS ON PROCESS EXPERTISE OR BESTWELD PRACTICES, IT'S TIME FOR SOMEONE

IN THE WELD SHOP TO STEP UP TO THE BLOODY PLATE AND FULLY COMPREHENDTHE PROCESSES THEY USE.

2013: Note the typical wire feed control(current control) on one of the world'slargest selling MIG wire feed units.Miller,Hobart, Lincoln and ESAB havemade wire feed controls for more than 5decades, yet in 2013 not one wire feedcontrol sold provides information to thewelder on the selection of optimum MIGweld parameters. By the way I first wrotethis paragraph in the early nineteeneighties.

You can be sure each day that millions ofwelders around the globe are playingaround with a wire feed control like this,and they will end up placing a scratch orpen mark on the feeder.


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IN THE EIGHTIES ED DEVELOPED A UNIQUE MIG / FCAW PROCESS CONTROLTRAINING METHOD CALLED THE "WELD CLOCK METHOD". THIS METHOD HASSIMPLIFIED WELD PARAMETER SELECTION AND EVOLVED OVER THE DECADES

The Weld Clock Method is based on the fact that traditional, none digital wire feedersdeliver a wire feed rate of 600 to 800 in./min (15 to 20 m/min). The majority of global wire

feeders have provided this wire feed range since the development of the MIG process.

As with any training method, effective MIG process control teaching and trainingmethods should always look for the common weld denominators in the operating orselection of weld parameters.Lets start out with MIG welding and make the average, global wire feed rate for a typicalMIG "none digital" wire feeder, approx. 700 in./min.

Ed developed theMIG Clock Method over three decades. The weld parameter ClockMethod simplifies weld parameter selection for any carbon steel or stainless applicationand brings together the relationship between none digital and digital MIG wire feed

settings, the application thickness, weld size and weld deposition rates.

Most wire feeders will deliver approximately 700 in./min. With the ten wire feed settings,starting at 7 o'clock and finishing at 5 o'clock. Each turn on the wire feed control wouldtherefore deliver approx. 70 inch/min per-turn. When you place the wire feed at themiddle setting, 12 o'clock, this is the fifth turn,5 x 70 = 350 inch/min.
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PANASONIC BS: While Panasonic and other pulsed MIG equipment manufacturersinform the weld industry that their MIG equipment offers millions of wave form optionsfor the welds, it's important that the weld shop understands, that irrespective of theweld application, steel or alloy welded, with that CV MIG equipment there are only three"optimum wire feed settings" for each weld wire and weld transfer mode utilized.

Ed's Weld Clock Method: With an 0.035 (1mm) wire, themajority of optimum carbon steel and stainless gauge weldswill be made with short circuit settings found between the 10and 12 o'clock wire feed positions. Set the wire feed control atthe third setting which is 10 o'clock = 3 x 70 ipm = approx. 210ipm.

At 10 o'clock, this short circuit wire feed setting deliversapprox. 140 to 150 amp. This current is ideal for all manual

carbon steel and stainless common gage sizes 0.050 - 0.060 (16 gauge) applications. Setthe weld voltage at 17 volts and when training the welders, simply tell the welder to

remember a great start point for all carbon steel and stainless sheet metal MIG welds,is 10 o'clock. with 17 cups of coffee.

MIG or Flux Cored Weld Process Optimization can be this simple.To set a good Short Circuit weld remember this.

17 CUPS OF COFFEE AT 10 o'clock.

USING TRADITIONAL CV AND PULSED MIG EQUIPMENT? There are 3 easy toremember, optimum wire feed settings for every MIG weld transfer mode and and 3


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settings for any flux cored wire irrespective of the application. Want to learnthesesettings for all MIG wires?

ONCE YOU LEARN ED'S CLOCK METHOD YOU HAVE THE ABILITY TO ATTAINOPTIMUM WELD QUALITY WITH LOW COST MIG EQUIPMENT. YOU CAN APPLY THISUNIQUE EASY TO REMEMBER, SIMPLE APPROACH TO ALSO SET DIGITAL WIRE

FEEDERS AND ROBOT WELD DATA. THIS METHOD IS USED IN ALL ED'S BOOKS, CDsAND VIDEO WELD TRAINING RESOURCES.

Ed's Weld Clock Method is applicable to all digital feeders and robot settings.

Watch those robot TIMES and it's influence on RobotArc Starts - Stops.

At robot weld starts, it's critical for "consistent arcstarts" to have the weld gas flowing before the arc is

initiated. Poor arc starts occur if there is not sufficientgas, remember, its the arc plasma "ionized gas" whichis the conductor for the transfer of electrons across anarc gap.

A robot offers many timed functions that a manualwelder does not have to deal with. Robot weld time onthe pendent is rarely calibrated with the actual robottimes. A good thing to know if the robot timed
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functions are working, is use your ears, if you cannot hear the changes they aretypically not effective and you may need to increase the robot times. For example on aweld crater fill, you may put a second for the crater fill and the time for the crater fill maybe only a third of a second.

Preflow gas times, ac ignition times, and at the weld ends, arc delay and crater fill times

etc. With many robots, the different arc timed functions can accumulate. The arc ignitiontimes may combine with the gas pre-flow time which may combine with the time inwhich the robot examines the arc ignition before it allows the weld to commence. Theaccumulation of weld start function times can result in the robot being stationary toolong at the weld start.

If a robot sits too long at an arc start when welding thin gauge parts, it's common to findthe weld size at the weld start is twice as big as the rest of the weld. The bottom line isthe with thin gauge welds only use robot times at the arc start if weld start issues occur.Arc start data becomes much more relevant on parts > 3 mm.

ROBOTS REQUIRE UNIQUE CONSIDERATIONS FOR WELDING GAUGE APPLICATIONS.ED'S ROBOT BEST PRACTICES - PROCESS CONTROLTRAINING CDPROVIDES ALLTHE SOLUTIONS AND THE ROBOT WELD DATA NECESSARY TO OPTIMIZE ALLCARBON STEELS AND STAINLESS ROBOT WELD QUALITY AND PRODUCTIVITY.

To see the worlds best weld process for > 16 gage alloy welds, check outTIP TIG:

MIG WELDING COSTS? In many welding shops there is oftengreater concern for the cost of the welding wire or gas, than there is

for the cost of the weld.

The objective of a MIG weld decision maker should be simple.Every time the welder presses the trigger on their MIG or flux coredgun ensure the weld settings selected should deliver the desiredweld quality with the wire feed control set as high as possibleproviding the highest deposition and therefore the lowest weldcosts.

Placing focus on attainable optimum wire feed and weld deposition rates for a specificweld application, is achieved through this weld process controleducation.

Weld Question: Ed. How does the welder know how much weld, they or arobot will deposit when using the 0.035 (1 mm) wire?

Answer: Its simple. With my unique clock teaching method. For each turnon a traditional wire feeder, the welder feeding the 0.035 wire at 70 in./min,delivers approximately 1 lb/hr (0.5 kg/hr) per-turn. So with the 0.035 set atthe 10 o'clock (210 inch/min) short circuit position, the 10 o'clock setting is
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the third turn and this provides approx. 3 lb/hr. The robot arc on time per-hr is 20minutes, so the robot deposits a one pound of wire each hour.

Any MIG or flux cored wire and any weld application. Once Ed's weld process trainingisprovided,weld quality and production objectives are fully understood and Weld CostCalculations are Made Simple.

You can attain your complex weld cost calculation tables from yourweld equipment or consumable suppliers who are typically ready to pullanything out of their hats to get your weld equipment and consumablebusiness. Or deal in Ed's world and use a very easymethodto controlyour weld costs.

Let's see, all I have to do to control welding costs isprovide the weld personnel with Ed's self teachingMIG process control books, or provide thisorganization with process training with the ProcessControl trainingProgram.These resources willkeep the the weld shop focus on wire feed anddeposition rates using Ed's easy to remember WeldCost Clock method. Then I should make sure myengineers, technicians and supervisors keep their eyes on thewire feed settings used daily in the shop. Well now, that's worth

looking into.

Weld Question: Ed. How do I know if the traditional none digital wirefeeder we use delivers the traditional wire feed range of 650 to 750 in./min(16.5 to 19 m/min)?

Answer: Every person who has to use a wire feeder that they have neverused before would benefit from the following especially if you go for a joband are required to use a wire feeder you have never seen before. Also

this simple test will let you know if your wire feeder is working correctly.

[] Set your wire feed control at the "12 o'clock position"[] Set the digital wire feeder at 350 inch/min

Press the gun trigger for 10 seconds you should have approximately 60 inches (1.5 m)of weld wire. Place one end of the wire under your foot and the other end should cometo the top of the average size guy's chest.
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2007: NOT ALL WIRE FEEDERS USED IN A WELD SHOP WERE CREATED EQUAL. Inthe eighties as part of a ridiculous marketing ploy or con job, some wire feedmanufacturers like Hobart sold high gear ratio, MIG wire feeders that fed the weld wirefrom 1000 to 1500 inch./min, (25 to 38 m/min). Other wire feeders were sold that fedmuch lower wire feed rates


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REGULAR TIG: Play this videofirst: Regular TIG typical manual weldspeeds for these weldsis typically 4 to 8 inch/min.

The TIG arc on time for this 12 inch weldwould be around 2- 3 minutes.Take a lookat the irregular weld quality influenced bytoo many arc start / stops, and take specialnote of the large heat affected zone that'sgoing to create distortion concerns.

Someone can always do a better TIG weld

than this but it will never match the qualityand productivity attained with TIP TIG.

TIP TIG: Manual TIP TIG weld travel rate48 inch/ min as noted on the UTube second

counter with this 12 inch length of 3 mm weldmade with an arc on time of 15 seconds:

Note the uniform weld quality that comes fromthe constant wire feed rate and only one arcstart / stop. Examine the smooth clean,unoxidized weld surface, the very small HAZand lack of weld distortion and weld minimalfumes. Think about the savings that will resultsfrom less cleaning.

From welding small, long track, 3 mm filletwelds on the deck of an Aircraft Carrier to the

small size stainless welds typically found onfood and beverage / processing equipment, noother weld process can provide long, small sizegage welds with the TIP TIG quality and thelowest possible weld heat input.

VisitTIP TIGmanual and Automation.

Too many weld shops provide their welders with undersize oroversized MIG contact tips or gun nozzles, this is simply anotherindication of lack of weld management.
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Poor tip diameter OD 3 mm. Nozzle ID 9 mm.

How can an industry that has more than50 years of MIG process expertise, handout to the welders in it's facility contacttips that are the no thicker than the endof a pen and nozzles so small that theybecome blocked with spatter in minutes.

Many of the plants that I have been inthat were welding gauge to 6 mm metals,provided their employees with ridiculousthin (< 3 mm) OD contact tips. With

these undesize tips (LEFT) they wouldthen provides nozzles with ID diameters of approx. 8-9 mm. Withthis situation,the MIG gun nozzle ID was so small that after five minutes of weld time the nozzleswould be s blocked with spatter or the contact tip will have shorted to the nozzleinterfering with the current flow. You can bet when they are handing out the wrong tipsand nozzles that they don't have control of the weld spatter.

In one last plant I visited, the welders in the plant did not seem to mind the ridiculous tipand nozzle consumables they were given as changing the tips and cleaning the nozzlewas more comfortable than doing the actual welds. Of course it's logical to use a smalldiameter nozzles when you cannot get a standard nozzle size as shown in the rightphoto into the required weld space, however in many situations the weld joint restriction

is not the issue.

The other amazing thing is once a poor practice like the innapropriateselection of the gun tips and nozzles are in place, the weld personnel willoften not want to change to the correct consumables because "this is theway we have always done it"

The primary value of a weld is based on the wages paidthe employee and the costs of the weld wires and gasesused, The driving factor of weld costs is weld deposition

rates provided by wire feed rates and the weld current delivered throughthat $1 contact tip.In North America you typically have an annual cost per-welder between$40,000 and and a $60,000. Without the correct $1 contact tip to transferthe current in a stable manner and a $8 nozzle that allows the MIG gas to the weld, howmuch of your weld costs do you believe go flying out of the window every day?

Understanding the weld tools we work with and the weld deposition rate potential forour welds, now that will be a first for our weld shop. Let's face it, we either control thebloody weld process or let the process and the salesman control us.


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Question. Ed where do we position the contact tip for manual or robotshort circuit welds?

Answer. To use the lowest voltage for thin gauge parts which typicallyis required for short circuit welding 16 gauge, place

the contact tip flush with the nozzle.

Question. Ed, we short circuit 0.035 (1 mm) hydroformed gauge parts. On the seam welds, the lap

joints open up between the robot fixture holdpoints. We always end up burning through at this

area, any suggestions.

Answer: Use a manual welder or the robot to MIGspot weld the areas subject to problems. Don't

know how to set a MIG spot weld, it's in my books.

Any manual MIG welder or robot can become a MIG spot welder. You need no specialequipment, just a little technique and a little process knowledge that's found in mybooks. You can MIG spot weld any steel stainless, aluminum or alloy gaugeapplications.

Weld Question: Ed, as most of the wire feeders soldtoday provide a digital wire feed rate why bother with theclock method?

Answer: The Clock Method "simplifies" optimum weldparameter selection and it;s extremely easy to rememberany weld setting for all MIG and flux cored weldapplications.

Digital or none digital when you learn the clock methodyou end up with the ability to instantly set any manual orautomated weld without playing with the weld controlsor parameters.

Please remember the traditional, low cost, more durable none digital wire feeders canlast 10 to 20 years in a welding shop, and in 2007, there are over a million traditionalwire feeders out there. As a weld decision maker you will most likely have to work withthese common durable wire feeders. If you are a professional at your craft you shouldknow how to set that simple one knob wire feed control, rather than "play around" withthe controls. If you are a trainer this method is easy to remember, therefore it's easy toteach.


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When you combine the optimum weld volts with the optimum wirefeed, the optimum short circuit welding parameters will produce acrisp, consistent, rapid crackle sound.

The Sweet Sounds of MIG: Today the majority of MIG welders,use arc sounds as a method of fine tuning their weld parameters.Arc sounds are fine but they dont let you know if you areproviding the required weld deposition rates.

Welders and robot operators should know "the cause of arc


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sounds"and the "correct weld parameter weld control response" to those arc sounds".

The weld sweet spot or sweet arc sounds attained with short circuit transfer result whenthe recommended optimum wire feed and voltage parameters are used. The optimumweld current (wire feed rate) and weld voltage will result in the maximum amount ofshort circuits achieved each second. The more rapid the short circuit crackle sound the

more consistent the "spatter free" weld transfer.

THANKS TO LACK OF WELD PROCESS EXPERTISE,WELD SPATTER COSTS MILLIONS DAILY:

The welding industry spends millions daily on cleaning weldingspatter from its parts. The welding equipment manufactures evenbuild special electronic MIG power sources designed to try to

produce minimum weld spatter. The weld reality is this. For the majority of gaugeapplications, when welding with a low cost, durable, easy to use and easy to repairLincoln, Miller, ESAB, or Hobart 200-400 amp, CV power source, as this 20 year oldvideo show, set the correct short circuit or spray welding parameters and you will attainminimal weld spatter.

Weld Fact: Remember the key to minimizing short circuit weld spatter is to keep theshort circuit weld drop as small as possible and create the fastest rate of short circuitweld transfer. This is achieved working in the recommended SC wire feed range, andensuring the weld voltage is set to it's minimum.

You don't need to invest in a sophisticated Fronius CMT, Lincoln STT or a Miller RMDelectronic power source to control weld spatter, you simply use a traditional low costdurable, low cost CV power source and teach the welders or robot personnel to set thecorrect weld parameters. Most weld spatter occurs with short circuit transfer from atraditional CV power source because the welder has set their weld volts too high.

Your self taught welders may have 20 years of skills experience, however pleaseremember "welding skills are not weld process control expertise" Instead of investing incostly, unnecessary weld equipment which may be impossible for your electricians torepair, or buying loads of anti-spatter, surely its more logical to provide your welderswith some process controltraining.

LETS SEE WE HAVE BEEN BUYING ANTI-SPATTER COMPOUNDS FORTEN YEARS, AND WE ARE NOW LOOKING AT VERY EXPENSIVEELECTRONIC MIG WELD EQUIPMENT. WHY WITH A LITTLE WELDPROCESS KNOWLEDGE MY WELDERS COULD STOP PUTTING THAT COSTLY OIL AND

WATER ON THE PARTS AND WITH THE MONEY I SAVE, ICOULD TRY THAT MINOXIL AND GET SOME HAIRGROWING BACK ON THIS BUSY HEAD.

This picture proudly presented in a USA weldingmagazine, shows newly trained, Detroit MIG welderswelding truck frames. The worst MIG welds found in theindustrial world are found on in auto / truck frame plants.


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The excessive weld sparks seen in the picture, indicate poorly tuned manual MIG weldsas evident by the fire works display. The amount of weld spatter generated is excessiveand it's evident excessive wire stick outs are being used.

These welders in the photo were trained by a national auto training organization basedin Detroit, it's purpose to help auto companies with their weld issues. Obviously the

trainers at this Michigan organization placed little emphasis on teaching MIG weldprocess control.

It's a sad reality also that whenever you find bad manual MIG welds, in the same plantyou are sure to find bad robot MIG welds.

A Self Teaching, Weld Process Controlresourcefor less than $400may be thesmallest investment we ever make with the largest return.

How many companies are prepared to invest a few pennies persupervisor, robot personnel or welders, for weld process controleducational resources or a training program designed to optimizeboth the manual or robot welding in their organization?

Shoot, it seems the biggest impediment to the implementation of effectiveWeld Best Practices and Process Controls in my plant is the face thatstares back from my mirror.

Most of you reading this weld data will be aware that the welding personnelat your facility are not aware of all of the weld data presented at this site. I have a

question for the you, how important is it to your organization to attain MIG or flux coredmanual or robot weld process controls? If you think you don't need this type of welddata, do me a favor and try theMIG welding Spray Transfer quiz,and then ask your selfhow important is this MIG data to your organization

Consider how easy it is with this unique clock method to bring your weld personnel intoa lunch room put my CD in your lap top and project weld data that will optimize the MIGor flux cored welds. Reduce your product liability and eliminate weld rework. Get instantcontrol of your weld costs through optimum weld deposition rates. Get your weld shopinto a professional mode with management and weld personnel all walking the samepath providing consistent, daily uniform weld results. Become a weld shop that frownson individuals that play around with the process parameter controls.

HOW YOU CAN USE THE CLOCK METHOD FOR OTHER COMMONWIRES. Welding pipes or structural steels? Do you know theoptimum welding parameter range settings for an 0.045 (1.2mm)Alloy Rod E71T-1 flux cored wire, for welding a 1/4 (6mm) filletweld in the vertical up or over head positions?. What's the singleoptimum setting for that 1/16 (1.6 mm) flux cored wire? With theclock method its simple and of course flux cored is covered in my books.
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TIP TIG 409 16 GAGE SEAM WELDS.TIP TIG 409 16 GAGE SEAM

WELDS

IF VIDEO PAUSES PLAY A SECOND TIMEIf you compared short circuit or pulsed MIG with this TIPTIG seam weld or any other steel or alloy seam gaugewelds, you would instantly note the superior weld qualityfrom TIP TIG. While the MIG welds may have fumeconcerns, oxide formation, spatter, distortion and possiblyrequire manual cleaning or weld rework, in contrast theTIP TIG welds would not create these common weldproduction issues.

Customer wanted to see thequality and productioncapability for TIP TIG on this

seam application. Theautomated set up was easy,

just attach the TIP TIG torch tothe auto carriage. Nosophisticated equipmentrequired like complex plasmaor Arc Volt Controls. Within 10minutes the TIP TIG wasproducing the parts shown onthe left. With automated TIP TIGseam gage welds such as this,you can anticipate the weldswould be made between 25 - 35

inch/min. (500 to 700% quickerthan manual TIG)

Documents

MIG Welding Gauge Steels and Alloy Steel Part1