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Other stories filed under Student Life. FPS starts season. Hybrid Hornets host open house. Tipton crowned homecoming queen. Twelve students comprise homecoming court.
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Kearsley takes a year off. Seniors lead Spirit Cup, juniors win banner contest. Brown crowned powder puff King. Senior powder puff court eyes crown. Juniors represent Class of on powder puff court. Spirit days celebrate Homecoming. Note: As you can see with above ships weld preps, the fitters in this ship yard must have got their training at Walmart and the engineers, QA personnel, supervisors might as well have stayed home.
One thing ignored in many ship yards is a "small fraction of an increase in the groove root opening" beyond that specifed will dramatically increase the number of weld passes required. The additional weld heat from the extra weld passes can influence, enlarge and weaken the steels Heat Affected Zones, esecially when the good practice of interpass tem controls are not applied which again is the norm.
Note: With larger than normal HAZs, mechanical strengths are decreased and minor weld defects will have more of an opportununty to influence weaker HAZ. Each year, ships that typically can cost to million dollars, will in decent weather, simply tear apart and sink, yet no one seems to know why. However with the ships in which someone as above, managed to take a photo before the deep plunge, the destructive metal tears will Imn sure in most instances follow the welds, and if you are looking for root causes of poor weld quality and over heated weld HAZ locations, simply track down the engineering and QA management at the yards where the ships were built.
And after my two day process control training program, we sent them back out to the yard. Over the next few months the skeptical QA department management religiously tracked and reported the weld rework labor - NDT - consumables reduction costs for one ship. They then followed up with a report to the yard management that the savings at that time were close to 6 million dollars. The reason that the ABS and also some of the AWS welder qualification tests on thick plate that require multi-passes are usually a complete waste of time and money, is once a welder has shown the ability to provide an optimum, "vertical up single pass.
Therefore all that should then be required is that the welder be taught the process controls for the process - consumables utilized, and the best weld practices necessary to comply with real world weld procedures, and with the typical numerous ship yard variable that influence the welds. Note: Another issue for many weld shops. Using an 0. This low cost weld should be the only welder qualification test ever required for any positions VEE or J groove plates.
To test the weld fusion attained, provide a break test in a vice. This will reveal the internal quality of the weld. Use the Spray mode. Beak test in large vice. As i have mentioned many times on this site, and as I have done at numerous weld facilities, when the weld shop employs weld management - engineers and supervision that has expertise in weld process control and best weld practices, that shop should be able to take someone who has never welded and with 5 to 8 days with my recommended training program have them pass any weld code requirement, all position welds using either the MIG or flux cored process.
Ed what is a weld professional? Answer: A professional welder is someone who fully understands the metals welded, the common arc weld processe and consumables utilized, the weld process control requirments, the best weld practices, and provide the necessary skills required for each application.
The above welders are taking the standard ABS gas shielded flux cored welder qualification test for a ship yard. From my perpective they are wasting their companies time and money putting "multi- pass" flux cored welds that simply repeat the welder's capabilty many times. An irony also is most of the welder are also using a weld process and consumables for the test, and yet its likely that both they and their supervisors, do not fully comprehend the weld process and consuamble requirementsto necessary to attain weld process optimization out in the ship yard.
O well its only been this way for sixty years. First put the potential new employees in a classroom. My classroom training requires approx. My recommendations for the hands on training are spelt out in my training programs. During the hands on, the welders would be examined for their attitude and ability to control the weld gun.
Note at this time the weld trainer decides if the weld person is ready for the welder qualification tests, should be let go, or requires a few more hours of hands on training. When you train any personnel so that they understand the process they use, and give them the optimum best weld practices and techniques that are required for the consumables and applications they work on, you should be able to get at least 8 out of 10 personnel through any welder qualification test and thats weld cost effective.
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Please remember I have done this on numerous occasions, it works. If a welder using the common E71T-1, gas shielded flux cored process can provide a one side, vertical up 5 - 7 mm fillet weld that will pass a break vice test, that welder should be capable repeating that weld and therefore when provided with FCA weld process controls and best weld practice training pass any position groove plate weld test.
All multipass all position groove welds should be made up of 5 - 6 mm fillet size stringer beads. The weld data is set for either a flat which is also used for horizontal welds, or for a Vert Up fillet beads which is also used for over head and all cap welds.
Flux Cored Wires:
The stringers with the optimum size weld energy to mass ratio, are directed at the location requiring the weld fusion. Most weld defects will occur from the root to the next two passes. Lack of fusion porosity and slag issues will be dramatically reduced if manual welders are not allowed to use weld weaves.
On any welder qualification test or in any plate goove steel flux cored application; A ceramic root and cap weld stringer passes will use the same flux cored "low" WF - volt settings. All vertical up and over head goove welds will use one WF - volt setting. Flat and horizontal positions will again use one higher WF - volt setting. These flux cored for all plate and pipe tests, and you know where to find those optimum plate or pipe weld settings.
As we are all hopefully aware, when optimum, multi-pass welds are required, that weld will be best served with 5 - 7 mm stringer beads as shown above. These stringer welds which are easy to control, will have about the same weld mass as found in the common 6 mm fillet welds. A 6 mm fillet should have excellant proportion between the weld energy provided and the weld mass produced. If a welder can pass a simple, single pass, fillet weld break test for the weld position desired, i t makes no sense for that welder to keep repeating the stringer welds over and over again.
I dont believe that most weld codes stipulate that it's a bad weld practice to allow manual welders to use weaves on code quality applications, if however welders avoid weaves they will get many weld benefits.. The weld wire used was E71T This welder qualification test was made by one of the ship yard qualified welders who from my perspectiveshould never have been allowed near a MIG power source. This individual, I will not call him a welder was out there in the yard making welds like this all over the ships, and the weld inspectors rarely took a second look.
This weld qualification test piece was made by the same welder who made the weld on the LEFT two days earlier.
Flux Cored and MIG plate and pipe weld issues and resolutions|
The welder used the same consumables, and after only 6 hours of my classroom process control training and 4 hours hands with the the best weld practices, the changes were dramatic. While the vertical up welds on the right were not optimum, the multi-pass welds did pass both an X-Ray evaluation and bend tests, and for the Aker ship yard share holders, that's money in the bank. Even when the welders have the highest possible skills, this type of training allows them to optimize the performance of the tools weld equipment they uses which increases both the weld quality and productivity capability.
What was also important, was each welder became aware of the unique flux cored weld parameters and technique and best practice requirements necessary to address the extensive different size root gaps over the ceramic. The improvements by all the welders was immediately noticed by the ship yard QA management who's inspection employees measured the dramatic weld cost improvements evident through the required NDT and weld rework man hours. Aker initially gained at least 5 - 6 million dollars per-ship from a weld training program that with a loss of man hours from the yard was a cost of approx.
By the way, few global ship yards or manufacturing facilities examine the cost effectiveness of the costly training programs they develop. Special thanks to Tom O'Malley blue jkt above.
Tom was like a brother to me, he is now deceased and really missed. Tom assisted me with the training program. By the way Tom was one of those rare owners of a weld supply company that actually spent many hours per-week evaluating the weld processes, equipment and consumables he sold. Neither the Canadian Navy or the North East Canadian ship yard management were aware that there was daily weld process chaos in the ship yard: During the nineteen nineties, I was invited to provide a weld evaluation for a large, North East, Canadian Ship Yard.
The yard had a contract to b uild Frigates for the Canadian Navy. After a tour of the yard, I found that the welding practices used by most of the welders could only be defined as "beyond chaos". The engineering - production management at this Canadian ship yard had enabled extremely poor, numerous and inappropriate weld practices to be used to construct the Frigates. There was a complete lack of understanding not only by the yard management but throughout the yard from the majority of weld personnel with both the MIG and flux cored weld processes which were the two prime processes utilized.
It was also interesting to note, that thanks to the lack of management process ownership and weld accountability from the yard management - supervison, the few weld engineers in the yard that had an inkling something was wrong, were not allowed to correct the welders and tell them what to do. The bottom line was the ship yard weld quality and productivity was run by the yard welders, and the vast majority of these welders lacked an understanding of the MIG and flux cored processes utilized.
Both of these two weld processes would attain a typical, average weld deposition range of approx. Each 8 hr shift t he welder would deposit approx. Note: A reflection of the common poor ship yard weld management is they will often find their welders in an 8 hr shift may average 10 - 15 pounds of weld metal. If you simply ask the purchasing mgr how many pounds of the two most important weld consumables are purchaed each year, then divide by the weld man hours for the year the ship yard weld efficiency can be readily worked out.
To compete in a global weld market in which the Chinease are building - welding bridges for the state of California, and maybe one day frigates for the US navy, one would think that engineering management involved with any large scale weld projects would at least understand the daily weld production deposition potential. Management that lack process expertise will often encouraged the welders to go BIG. These 15 mm, single pass fillet welds made in flat position on rock crushing equip - high strength steels led to excess weld heat in the HAZ, that lead to very costly equipment failure.
The management was not aware that smaller, stringer welds provide the same weld production with the faster weld speeds that also keep the weld heat input low.
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Also excess weld heat will be generated from the large welds and slow travel rates. The Canadian ship yard welders when making a horizontal fillet weld, would do the following. No one could answer why the welders were using short circuit with the MIG wires, the reality was it was hard to find someone in the yard that knew what short circuit was. The MIG short circuit parameters utilized throughout the yard would have been better suited to welding hin gage 0.