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WELDING CONSULTING SERVICES

 

INTRODUCTION

    Welding design and fabrication questions and problems affecting quality can come up when least expected.  Therefore having a welding consultant available who has the right answers and solutions, certified welder experience, and a real welding engineering degree are essential to avoid welding mistakes, and ensure welding quality.

BACKGROUND    
    

    Weldments must meet increasingly stringent performance requirements.  The economic and human costs of failure during service in today's litigious society impose a great responsibility on those who design weldments, and those who select and integrate welding processes and materials to produce the final weldment design.  A critical feature of successful weldment design is the selection of the best material based on an awareness of the capabilities and opportunities afforded by all candidate materials, coupled with a design which takes full advantage of those capabilities, including weldability and fabricability.  This takes a team effort, which requires the support of a welding engineer's unique knowledge and experience. This support is necessary due to a widespread lack of welding knowledge in industry because welding is not generally taught at the four year university or college level to engineers, except to those in a welding engineering degree program. This lack of welding knowledge shows up in the work place as welding mistakes that cause welding problems when the untrained engineers must specify welding design and fabrication requirements.  Let's be clear, when used correctly, the science and technology of welding are enabling disciplines that make high quality, low cost weldments possible.  Therefore, to get the maximum economic and technical benefits, you must have the welding knowledge to properly select and apply the science and technology without making mistakes.

PROBLEM  

    The problem is, most firms that design or fabricate weldments typically have no one on their staff with a welding engineering degree to establish and specify welding requirements.  This limits their ability to answer welding questions, prevent and solve welding problems, and interpret and apply the welding and fabrication requirements in applicable welding codes, standards and specification, which can be especially challenging to the layman user or specifier.  The firms therefore mistakenly rely too heavily on welding inspection to control and improve welding quality.  You cannot inspect in welding quality.  Welding inspection is necessary but it's not enough, because even when welding inspection is done correctly, it typically occurs after the weldment has already been designed or built.  Therefore welding quality or lack of welding quality has already been designed or built-in the weldment.  Therefore welding inspection can only confirm or verify the welding quality that's already there, good or bad.  To ensure good welding quality, you must first design in welding quality before you can build in welding quality.  Welding quality must become inherent in the design, procurement and fabrication process by avoiding mistakes.  Neither can welding inspection be substituted for welding engineering.  The welding inspection function does not establish welding requirements.  The welding engineering function does.  The role of welding inspection is to confirm or verify that the welding requirements established and specified by welding engineering is implemented without making mistakes.  One welding mistake can cost millions. Three cases in point: (1) The attempts of some engineers and designers to specify SA 335, Grade P91, 9Cr-1Mo-V steel pipe, because of its long term high temperature properties.  And as a result having the material fail prematurely in service due to improper fabrication, welding, and heat treating procedures.  (2) The improper weld joint, and weld, causing the cracked pipe weld, gas leak, explosion, and fire in San Bruno, California, resulting in several deaths and extensive property damage.  (3) The weld cracking problem on the new San Francisco-Oakland Bay Bridge.  Typical mistakes leading to these types of problems include: 

  • No one with a welding engineering degree to support the weldment design function...
  • Using someone who does not have a welding engineering degree to make welding decisions...
  • Assuming metallurgical and materials engineering are equivalent to welding engineering...
  • Relying solely on text books and handbooks to select welding filler metals and electrodes...
  • Relying solely on welders for information affecting engineering and design decisions...
  • Relying on welding inspection to control and improve welding quality...
  • Not considering, or understanding the changes occurring in the base material, and weld heat affected zones during welding...
  • Assuming a certified welder will always make good welds...
  • And others... see a complete explanation of these mistakes and others by clicking on COMMON MISTAKES TO AVOID in the left side frame.

SOLUTION 

    The firm performs or provides assistance with welding activities, answers technical questions and advise designers, engineers, fabrication and quality personnel on matters of welding during the design, procurement, and fabrication phase  needed to design and build in welding quality, by avoiding mistakes, and thereby ensure weldments are suitable for the intended purpose.  This service can also be provided to your contractors, subcontractors, vendors or suppliers.

$    It's most costly to correct mistakes found in the finished weldment.

$    It's less costly to correct mistakes found when making the weldment.

   It's least costly to prevent mistakes during research, development and design of the weldment.

 

BENEFITS OF WELDING CONSULTING SERVICES

Welding consulting will allow you to:

  1. Prevent common welding mistakes that reduce quality, lower productivity, increase costs, and jeopardize safety.

  2. Improve your technical capability in welding.

  3. Eliminate the expense and commitment of hiring and maintaining a full time welding engineering support staff.

  4. Get the practical hands-on experience and knowledge required for the success of your project.

  5. Get solutions to problems or an independent opinion when needed.

  6. Profit from your project investment through improved quality, cost reductions, and on time performance within budget.  In other words you receive the best value for your investment dollar.

  7. Prevent unnecessary lawsuits resulting from mistakes, failure or safety incidents.

  8. Design and build in welding quality.

    For your convenience some of the welding consulting services can be performed remotely saving you the time and cost associated with having an engineer travel to your location. If you prefer to have an engineer visit your location, or the location of a vendor, supplier, contractor or subcontractor, an hourly rate, travel time, mileage and associated expenses will be charged.

    To get a cost estimate for welding consulting, or location visits, click on CONTACT METHODS in the left side frame, and use any of the listed methods to contact McWane and Associates.