Self Teaching and Training Resources for Robot & Manual MIG, Flux Cored, Advanced TIG + TIP TIG, Weld Process Controls and Best Weld Practice

E Craig has over 50 years of weld process controls & best weld practice expertise.

In 2017 Ed assisted United Technologies, with NASA – Boeing weld projects that are part of the Space Station and part of the ORION MARS Space project..

A message from Ed Craig. Welcome to weldreality.com. Over the last four decades I have been developing and updating the following 5 Weld Process Controls – Best Weld Practice Training / Self Teaching programs. Thousands of companies and personnel have purchased these progams and seen dramatic improvements in their weld quality and productivity. And I have utilized the same programs to provide weld quality – productivity improvements and training to over 1000 companies in 13 countries.

Weld Process Controls & Best Weld Practice,
Self Teaching /  Training Programs.

Item ONE. The Manual MIG program.

Item TWO. The Gas Shielded Flux Cored program.

Item THREE. The Robot MIG Weld Process Controls – Best Practice program.

Item FOUR. “The Weld Management – Engineers Book to MIG and Flux Cored. With this  book, you also get your choice of any of  Weld Process Controls – Best Weld Practices training programs in items  1 – 2 – 3 – 5.

Item FIVE. Advanced TIG  Weld Process Controls & Best Weld Practices Training – Self Teaching Programs. This unique three part TIG  program would benefit anyone in the Aerospace, Defense, Power, Oil, or Medical industry.

What do NASA, Lockheed Martin, Northrop, Raytheon, GE, Westinghouse,  SpaceX, Airbus, Fluor, Bechtel and most other high tech – engineering companies have in common in 2017? Most of these companies and the industry they represent are using OUTDATED Weld Specifications & Weld Procedures, and too many of their engineers that are involved in daily weld decisions, lack the TIG. (or MIG) Weld Process Controls – Best Weld Practice expertise that is necessary to ensure their companies will consistently attain the highest possible weld quality and productivity.

If you want to provide for yourself, or for someone in your organization with the ability consistently attain or to train employees to achieve the highest possible, code quality manual & automated TIG welds, and also to be able cut through the numerous, ever evolving TIG  Inverter weld equipment bells / whistles. Item 5 also includes weld process optimization through using the evolution of TIG, the TIP TIG process.
Note Ed bought the TIP TIG process to North America and to  Australia.

Scroll down for extensive data on the above training programs, and also information on how to order using Pay-Pal or regular Credit Cards.

Some in the front office may ask, why do we need  MIG, TIG or Flux Cored manual or robot Weld Process Control – Best Practice Expertise, when we employ many experienced welders?

Weld Process Controls and Best Weld Practices are not taught in most global educational institutions that provide weld programs. If the criteria for hiring weld personnel was based on this expertise then few would get hired.

The global weld industry is an one that it would be rare to find weld shops that have discussions on their  level of  MIG – TIG or flux cored weld process controls –  best weld practice expertise.  As global weld shops struggle to be competitive and weld liability concerns increase process controls and best practices are subjects which in reality are the “missing links”  which are necessary for management, supervision and other decision makers to be able to consistently attain the highest possible Manual or Robot arc weld quality, always of course at the lowest weld costs.

My unique self teaching  / training programs are based on the weld process quality – productivity  improvements that  I provided in 1000 plus companies in 13 countries. In developing the programs,  I focused on the weld process parameter common denominators and best weld practices necessary.  To simplify the presentation of the data, I developed the Weld Clock Method which has evolved of three decades. This method makes the subject easy  to learn and remember.  On average it took me 2000 to 3000 hours to produce each of the five programs offered.

The programs are directed at any weld decision maker, and this includes managers, engineers, trainers, educators, supervisors, technicians and of course welders. These are the programs that will dramatically  eliminate weld quality – productivity and cost issues. And most important, they  will  eliminate the need for those experienced weld personnel to stop “PLAYING AROUND” with their weld controls.  These type of programs are not available from any other global educational or training organizations.

Why would and experienced manages, engineers or supervisors be concerned about the need to hire  NEW WELDERS?

If the correct process control – best practice and hands on  training is provided, with the common arc welding processes,  it would typically takes less than two weeks for the training,  and for the most stringent code welder qualifications, less than a month to enable any individual (no weld background) to pass the required welder tests.  In reality the so called global welder shortage, simply reflects on the lack of experienced weld managers, supervisors, engineers and trainers.

2017: The GTAW (TIG) process requires the most arc welding skills, however for more than a decade, the weld industry has had access to the TIP TIG process. This process typically can be taught to none welders in a few days. It also dramatically lowers labor costs, while providing higher weld quality than any manual or automated regular TIG,  or Hot / Cold wire TIG weld.

GET BETTER RESULTS FROM THOSE  “EXPERIENCED” WELDERS: You could take any “experienced” weld personnel and provide them with 8 – 12 hrs of my Process Control – Best Practice training, and all of a sudden they will stop playing around with their MIG – Flux Cored weld data. Your weld rework will be greatly reduced and optimum weld productivity at the lowest weld costs is consistently attained.

Note: Also please check out what an amazing influence these programs have on your robot technicians as the majority have never had process control training.

MORE REASONS TO CONSIDER THE PURCHASE THESE PROGRAMS.

If you use the “MANUAL OR AUTOMATED” MIG & TIG and the Flux Cored process, the following programs will provide the following benefits;

  • OPTIMIZING WELD QUALITY: This resource enables weld personnel to stop “playing around” with the weld controls and provides the optimum process requirements that are necessary with any weld application, to consistently attain the highest weld quality with any manual / robot weld application.
  • OPTIMIZE WELD PRODUCTIVITY. These manual and robot programs provide the process expertise necessary to attain with the lowest cost weld consumables & equipment, as well as optimum quality, the highest possible weld deposition rates. This results in the lowest weld labor / robot costs.
  • SIMPLIFY ALL MIG – FCA WELD COSTS: The programs provide an easy method for any weld personnel to in a few minutes, figure out the weld costs on any applications.
  • WELD CLEAN UP AND WELD FUMES: The programs enables the weld process expertise to consistently produce minimum spatter & welds with the lowest possible weld fumes.
  • WELD DEFECTS & INSTANT WELD RESOLUTIONS: The programs provide weld personnel with the MIG and flux cored weld process controls and best practice expertise that will enable the least amount of manual or robot weld defects and also the least possible robot down time.
  • SPEED UP WELDER TRAINING & IMPROVE THE WELD TEST PASS RATES FOR WELDERS. With these programs, even personnel that have had “NO previous MIG – flux cored weld experience” will be able to in a few hours, attain the highest weld quality and productivity and pass any AWS – ABS – ASME – API MIG – Flux Cored welder tests.
  • ELIMINATE PERSONNEL HAVING TO PLAY AROUND WITH WELD CONTROLS. This program enables weld decision makers to instantly select the most effective weld transfer modes with the wires utilized, and instantly set optimum parameters without playing around with the weld controls. With this expertise, any weld shop will have the ability to get the full potential from the weld equipment / processes utilized.
  • ELIMINATES THE NEED FOR WELD DECISION MAKERS TO ASK A  “SALES MAN” FOR ADVICE WITH PROCESSES THAT HAVE BEEN IN USE FOR DECADES. The training programs enable any weld decision makers to take full ownership of their important weld processes and easily reach their daily weld goals. This also dramatically reduce a companies Weld Liability Concerns and also enables them to justify the purchase of low cost MIG weld equipment and the weld consumables utilized.

WHAT ABOUT THE PERSONNEL THAT ARE
RESPONSIBLE FOR THE ARC WELDING ROBOTS?


MIG WELDING AND ROBOTS:
 From robot MIG welds on truck or car frames, to the welds on car seats or heavy construction equipment. It does not matter what the MIG weld application is, with the implementation of my “Seven Step Robot Weld Process Control – Best Robot Weld Practice Program,” any company could quickly achieve process ownership and the following.

  • ROBOT WELD QUALITY: Within minutes in a robot cell, apply the optimum robot program weld process control data and apply the best robot weld practices that will ensure the highest possible weld quality leading to minimum weld rejects and rework.
  • ROBOT WELD PRODUCTIVITY: With this training program robot personnel will have the expertise necessary to ensure the maximum possible robot weld speeds with each weld produced, and daily consistently attain the full weld production potential.
  • ROBOT WELD EFFICIENCY: Provides the process controls – best practice expertise necessary to optimize arc on times, and minimize the robot down times. This combined with the the consistent ability to attain the highest weld deposition rates ensures the highest possible weld production from each robot cell.
  • ROBOT PROGRAMMING TIMES AND SIMPLIFY ROBOT PROGRAM DATA: This program enable robot programmers to dramatically reduce their robot programming times and simplify the weld data used. Note: It took the author less than 4 hours to program the approx 150 – 200 robot welds used on Harley Bike Frames and at the time this program was implemented none of these welds required weld rework.

This program also provides the most comprehensive and simple approach to eliminate the potential for robot down time and for weld defects. When  robot issues or weld defects occur, rather than watch the robot technicians “play around” with the weld / programming data  in the robot cells, why not provide the technicians with the process controls – best practice expertise that will dramatically reduce the defects.

  • UTILIZE THE COMPLETE PROCESS POTENTIAL FROM WELD EQUIPMENT. This program enables the full potential of the MIG process to be utilized by the robot programmers. For example programmers will know when to switch to a Short Circuit, Globular, Spray or Pulsed weld, and without “playing around” with the data in the robot cell” instantly provide optimum weld settings for the weld transfer modes selected.
  • FRONT OFFICE PERSONEL SHOULD APPRECIATE A PROGRAM THAT SIMPLIFIES THE ROBOT WELD COSTS ON THEIR PARTS. This program enables front office personnel within a few minutes to provide accurate robot MIG weld costs per part welded.
  • REDUCE ROBOT CELL EQUIPMENT / CONSUMABLES COSTS. Front office weld decision makers should be aware of the best and the lowest cost peripheral robot equipment – weld equipment and weld consumables.
  • BE AWARE OF WHAT GOES INTO THAT ROBOT PURCHASE ORDER. Weld decision makers should be aware of the logical robot purchase contract requirements which can minimize the opportunity for robot weld quality – productivity issues with new robots.
  • PROVIDE CORRECT ROBOT WELD JOB DESCRIPTIONS: Enables managers to provide effective and correct job descriptions which are required for robot weld optimization.

E-Mail.
Ed your Weld process control – best practice training programs are awesome and provided much more than I expected. We are seeing instant MIG and flux cored weld quality and productivity results. Thanks Ed…Regards. Tony Pasqualetto… pasq@shaw.ca

E-Mail.
Dear Ed. I am writing you to mention that I am leaving the active duty with Bombardier Transportation, heading to my retirement, beginning the 1st of March.

Ed I am glad that our roads have crossed. I have always been impressed by your competence, dynamic attitude & action, and most of all by your incessant combat for common sense and against ignorance. (Please refer to the attachment.)We appreciated your wise technical weld process advice and example: listen to your own competence and judgment, and resist to marketing propaganda.

Regards and All the best. Wladyslaw Jaxa-Rozen, P. Eng., IWE
Fellow Expert – Welding and Materials. Bombardier Transportation – Americas
St-Bruno, Québec.

Note: Bombardier is the world’s leading manufacturer of both planes and trains. Bombardier has built an extensive and diverse portfolio of winning mobility solutions. Everywhere people travel by land and in the air, a Bombardier product is ready to transport them. From category-defining business jets and commercial aircraft designed for the challenges of today, to sleek high speed trains and public transit that’s smarter than ever. With 70,900 employees, Bombardier is headquartered in Montreal, Canada. In 2015, Bombardier posted revenues of $18.2 billion.

ORDERING: Note: Some of you have called and stated you cannot use PAYPAL to order, as your company does not have a PAYPAL acct. Please be aware that with PAYPAL you do not need to use the PAYPAL acct. PAYPAL also provides the option for you to use your regular credit card, (claim as an expense), or use a company credit card.

For those of you that work in companies that have a fire wall in place that prevents the acceptance of large E-Mails, please provide an alternative E-Mail address (such as your own e-mail address). Part of the program will be delivered by We Transfer E-Mail, and the books and DVD by USA Priority mail. These programs are not refundable.

The following is a brief description of the available training items. For extensive info and to order, scroll down the page to the specific items that you have an interest in.

Item 1,  A Self Teaching & Training Program for MANUAL MIG Weld Process Controls & Best Practices

  • Consistently enable the highest possible MIG weld quality and productivity.
  • Dramatically reduce Manual MIG weld rejects, repairs & liability concerns.
  • Dramatically reduce weld spatter and MIG weld cleaning.

While some weld equipment mfgs. provide MIG equipment loaded with costly, useless electronic bells and whistles, or tell your company about the millions of weld form waves available from their over priced MIG power equipment, this resource cuts through the sales BS and provides THREE easy to remember sets of MIG weld data that will ensure optimum MIG weld quality and productivity for any MIG weld transfer mode used. The bottom line is with the purchase of this resource a weld shop will finally have weld decision makers who will no longer have to “play around” with their MIG weld controls.

This program enables weld decision makers to dramatically reduce their weld shop equipment and  consumable costs.

Finally a program that provides a a simple method to work out and provide real world weld costs – quotes.

The MIG equipment purchased may enable the Short Circuit – Spray – Globular and Pulsed Transfer Modes, the question is do those that operate that equipment understand the weld modes and their optimum parameters and their correct use on those steels. alloy steels, stainless and aluminum welds.

No other self teaching / training weld process control resource provides the comprehensive, real world, weld process control – best practice data found in this program. From Short Circuit welds on gauge applications to Spray or Pulsed welds on thicker steels. From carbon steels to aluminum and all alloy stl welds. From fabrication, to pipe welds, (or clad welds), you can get advice from a weld salesman, or get the practical, cost effective weld info that will always produce the highest possible MIG weld quality at the lowest possible weld costs

Includes:

  1. My Power Point Training Program “Manual MIG. Optimum manual weld Process Controls – Best Practices for all steels, alloy steels and aluminum applications”
  2. My 100 page Book. “Manual – Robot MIG Welding”
  3. My DVD film. “MIG Process Controls Made Simple”

Cost: $275.00, plus shipping, $30 USA & Canada.  Other countries $60.

If you can answer these process questions you don’t need these materials.

Ed’s MIG Weld Process Controls & Best Practice Test.



SCROLL DOWN FOR MUCH MORE INFO…

Ed. Your book and Training resource has dramatically impacted the weld quality and productivity in our company and as an additional bonus, it’s also improved my weld career prospects.

All the best mate. Nick Cooste. Australia.

Item 2. 

Gas Shielded Flux Cored. 

The following is a brief description of the available items. To order or for extensive information scroll down the page to the specific Items you want. When you order,  you will have two options to pay. With the PayPal Login use your PayPal account, or the other option is use the PayPal Box that enables you to use your own credit card info.


Item 2. 
Gas Shielded Flux Cored Weld Process Controls & Best Weld Practices”.

Here you will find the solutions to consistently ensure the highest possible weld flux cored weld quality & productivity when welding any all position flux cored structural welds, pressure vessels, pipes, tanks, or any type of groove welds including those with open roots, steel or ceramic backing.

Note If you are a welder and you want the easy to learn the solutions to pass any all position plate / pipe weld test required by AWS – API – ASME – ABS, this is it.

Gas Shielded Flux cored is a process that utilizes MIG equipment, and as common with the MIG process, most flux cored weld personnel will play around with the power source or wire feed weld controls.

The flux cored process is often used on all position, code applications that typically require optimum weld quality. For more than three decades, the manual / automated flux cored process has in the majority of global plants rarely been optimized. This is a process that even when used correctly can readily generate many weld defects.

When NDT is used for flux cored weld evaluation, the welds will typically reveal lack of fusion, slag worm tracks and excess porosity concerns. These defects and weld rework can be greatly reduced by weld personnel that have flux cored weld process control – best weld practice expertise.

With the gas shielded flux cored process, the weld shop should expect SLAG INCLUSIONS – POROSITY – WORM TRACKS – LACK OF FUSION OR CRACKS. The weld shop should also be aware that with weld process controls & best practice expertise you can minimize those defects.

Not only will the use of this program dramatically reduce flux cored weld liability concerns and weld rework costs, this program also enables weld personnel to consistently attain the highest possible, all position weld production, (highest deposition rates ) enabling the lowest possible weld costs.

WELD PROFESSIONALS NEVER “PLAY AROUND” WITH WELD CONTROLS. No weld shop should be proud that some of it’s weld personnel  “play around” with their weld controls. This resource will ensure that weld personnel will no longer have to “play around” with  weld controls, and instead rookie welders or highly experienced welders will be able to provide instant optimum weld parameters and the weld practices that are necessary in most weld shops to deal with the many variables that daily influence the weld quality / productivity.

With my weld process control CLOCK method, you only need to learn THREE easy to remember flux cored settings suited to all weld applications.

This program includes:

  1. My flux cored Process Controls – Best Practice Power Point Training Program.
    “Gas Shielded Flux Cored weld Process Controls – Best Weld Practices.
  2. My flux cored Book. “Flux Cored and MIG weld Process Controls”
  3. My Video (on DVD) to learn the Clock Method. “MIG Controls Made Simple”.

Cost: $275.00, plus shipping, $30 USA & Canada. Other countries $60.



If you could answer the questions in the following quiz, you would not  need this resource.

Ed’s Flux Cored Weld Process Control Test.

It pleases me sometimes when I am out in my car, and I view a few of the weld projects that I was requested to provide robot MIG weld quality and weld productivity improvements.

Item 3. 

Robot MIG Weld Process Controls
and Best Weld Practices.

The following is a brief description of the available items. For extensive info and to order scroll down to the specific Items you want and to place an order.

Item 3. “Robot MIG Weld Process Controls &  Best Weld Practices”

This unique, easy to learn, self teaching & training package, enables an organization to rapidly attain the best possible robot MIG weld quality and productivity,  always of course at the lowest possible weld costs. There will always be less concern for robot weld quality & productivity issues, rejects rework, recalls and liability issues, when Ed’s Seven Steps to Robot Weld Process Controls & Best Weld Practices  are implemented.

THIS PROGRAM PROVIDES THE MOST COMPREHENSIVE AND SIMPLE APPROACH TO ELIMINATE THE POTENTIAL FOR THE OFTEN COSTLY, ROBOT MIG WELD ISSUES / DEFECTS.

When robot MIG  weld issues occur, managers and supervisors can watch the robot weld technicians play around with the robot data or those same managers could provide the relevant technicians and engineers with something they have never been offered before,  ROBOT WELD PROCESS CONTROL & BEST PRACTICE TRAINING.

This program will enable the following;

  • Quickly optimize the robot weld productivity.
  • Minimize the robot down time.
  • Eliminate robot weld rejects & rework.
  • Achieve consistent, uniform weld results each shift.
  • Reduce future robot cell equipment – consumable purchase and costs.
  • Reduce robot training time.
  • Provide the robot weld solutions for weld gaps and poor fit parts.
  • Instantly provide solutions to the unique,  daily weld variables / issues that occurs with most robot welds on steels, alloy steels and aluminum welds.
  • Know when to switch between the weld modes & how to instantly set the best  parameters.
  • Know the unique requirements to attain the highest possible weld speeds and productivity.
  • In a few hours, participants of this program will become an expert in the world’s three most widely used MIG weld transfer modes, Short Circuit, Spray and Pulsed transfer.

Ed. First let me say that I regularly consult your Management MIG Weld book. Thank you for all the cool weld info. With your programs I feel that I am now in full control of this important process. By the way your unique robot MIG program data  has provided us with dramatic quality and productivity benefits and that section on MIG Wire Stick Out extensions and robot production  has enabled us to attain the highest possible weld deposition rates and fastest robot weld speeds. The advice was brilliant.
From Weld Engineer.
Hydroform Solutions.
Ontario. Canada.

Item 3. Includes:

  1. My Power Point, “Robot MIG Process Controls – Best Weld Practice Training program”.
  2. My 100 page Self Teaching Weld Book. “Manual and Robot Gas Metal Arc Welding”.
  3. My DVD Video: “MIG Made Simple”

Cost: $275.00, plus $30 shipping USA & Canada. Other countries $60.




THEY DON’T TEACH THIS STUFF AT ANY ENGINEERING UNIVERSITY OR COLLEGE. WHAT THIS UNIQUE PROGRAM CAN DO FOR YOUR CAREER.

When a manager, engineer, supervisor, technician, inspector or welder has the ability through weld process controls – best weld practices expertise, to instantly optimize the welding performance of the work force and the primary weld equipment used in the weld shop, that person is an important asset to their organization, and that person will have excellent career prospects. I wrote this in 1998 and its even more important in 2016.

Item 4.

“Weld Management – Engineer & Supervisor Book”.

With this book order you can order any Training Resource.

MIG Welding Management

The following is a brief description of the available items. For extensive info and to order scroll down the page to the specific Items you want and to place an order.


Item 4 Package includes the following Three items:

My weld Management – Engineers” Book;

[1] “A Management & Engineers Guide to MIG Weld Quality Weld Productivity and Costs.

This 600 page book is the most comprehensive practical book ever written for anyone that wants to cut the umbilical cord to the weld sales man, and manage a weld shop to daily attain the best possible, manual / robot MIG – FCA weld quality / productivity. Also the book has a unique section that deals with the requirements necessary for weld decision makers to attain the highest possible deposition rates and the highest weld speeds with robots or any automated welds. This is the only source of this data available anywhere in the world..

With this package you can also select one of my power point Training – Self Teaching Programs.

[2] Below you will be asked to select one of the following process control programs;

  • Manual – MIG.
  • Manual Flux Cored.
  • Robot MIG Weld Process Control program.
  • Advanced TIG and TIP TIG programe.

Item. 4 Cost: $475.00, plus $30 USA & Canada shipping.

Other countries $60.


Training Progam Options



When you order you will have two options to pay. With the PayPal Login use your PayPal account, or the other option is use the PayPal Box that enables you to use your credit card info.

Note: Within a few hours of PayPal accepting your payment, you will receive my power point process control training program on a “WE TRANSFER” E-Mail. The books and DVD will follow in the mail. Also those that purchase these materials can call me (no charge) anytime with weld questions. 828 337 2695 Eastern Time. Call between 10 am – 6 pm Monday – Saturday or E-Mail ecraig@weldreality.com…

Item 5.

“The World’s most Advanced
GTAW (TIG) Training
&  Self Teaching Program
.


Three UNIQUE TIG Weld Process Controls & Best Weld Practice Training Programs in one.

[1] ADVANCED AC TIG for all Aluminum welds.
[2] ADVANCED DCEN for all steels – alloy steel welds.
[3] The evolution of TIG. The manual automated TIP TIG process.

A 2017: A note to the Aerospace, Defense, Oil, Power, Nuclear and Medical industries. The majority of the Weld Specifications and Procedures used in these industries will too frequently point out how outdated these important weld control documents are, and also how out of touch most managers and engineers are who are responsible. Weld process control and best practice expertise are the missing links in these industries and are necessary for managers, engineers and supervisors to step into the 21st Century and take ownership and enable their companies to consistently attain the highest TIG  or TIP TIG weld quality and productivity with of course the lowest weld costs.

When a company purchases a costly new  Inverter  TIG power source,  they have purchased what is often termed an Advanced TIG power source, the irony is that the company too frequently  will have purchased TIG equip, that is simply ineffective in comparison to TIP TIG,  or the power source bells and whistles simply adds more weld process confusion for the weld shop.;

[1] BOTH THE TIG PROCESS AND TIG EQUIPMENT HAVE EVOLVED,  HAS YOUR COMPANY?

[2] TIG EQUIPMENT IS OFTEN LOADED WITH COSTLY, UNNECESSARY ELECTRONIC BELLS AND WHISTLES, WHO RECOGNIZES WHAT SHOULD BE UTILIZED, HOW TO GET THE BEST POTENTIAL FROM THE OPTIONS AND WHATS THE BEST WAY TO TRAIN THOSE TIG WELDERS WHO DON’T LIKE THE CHANGE INTRODUCED?

[3] TIG EQUIPMENT WITH AC / DC CONTROLS IS TOO OFTEN POORLY UNDERSTOOD AND TOO OFTEN THE CONTROLS THAT ARE BENEFICIAL FOR THE DIFFERENT POLARITIES ARE UNDERUTILIZED.

THE PRICE FOR NOT EVOLVING WITH WELD PROCESSES:

2017.. Today as its been for almost 70 years, most in the global weld industry still TIG weld the the way its been done for  decades. For more than a decade the TIG process has evolved into a far superior process called TIP TIG. In contrast to regular manual TIG or using the most sophisticated TIG equipment or the automated Hot Wire TIG process, the TIP TIG process will always;

  • produce superior weld quality,
  • superior metallurgical,
  • superior corrosion properties.
  • the lowest distortion,
  • the lowest weld fumes
  • the lowest all position skill requirements,
  • welds that cost tyoically  25 – 30% of the cost of a TIG weld.
  • easily automated with reduced arc length sensitivity.

Few companies can typically create TIG weld quality shown below. If you are an engineer involved with TIG could you now write down the requirements that enable this weld quality and the remarkable weld quality uniformity.



As the company that makes the above product is aware, welds like this take more than skills. 
My Advanced AC or DC TIG program, provides the  weld process controls and best practices that can with a skilled welder produce this type of quality.

What makes this Advanced TIG training program unique?

AS WITH THE MIG PROCESS, YOU MAY HAVE WATCHED SKILLED TIG WELDERS “PLAY AROUND” OR SIMPLY NOT FULLY UTILIZE THEIR WELD EQUIPMENT ELECTRONIC WELD PROCESS CONTROL FEATURES.

TIG been been around for at more than 60 years, so why should TIG weld process control – best practice training be necessary even for those “highly skilled” TIG welders?


The following are a few fundamental Process Questions that you could ask your experienced TIG welders.

[] There are three essential AC process control options that are required for all aluminum welds, what are they and why are they essential?

[] Explain the key weld attributes that can be attained from an AC TIG Hz control and a DC TIG pulsed control.

[] Your new TIG equipment has arrived, it has a Balance Wave Regulation Control.
What is it? —– Why is it required? —– What benefits do you get from it.. 

[] What is the difference of a Balance Wave Control and an independant amplitude control? Which is beneficial for your weld shop applications and why?

[] How does the AC Balance Wave regulation impact weld fusion or weld burn through?

[] What welds will it benefiT from an AC Hz Frequency control, and why.

[] Name three important benefits attained from a basic AC Square Wave control in contrast to a TIG power source usin a regular AC Sine Wave?

[] Why is it important when welding gage alum to use options that can enable you to stop using pure tungsten.

[] When should you consider DCEN Pulsed TIG, and why on many DCEN TIG welds
on parts > 3mm should this option be given careful consideration?

[] Explain how the TIG argon gas is responsible for removing the alum oxide for clean AC welds”

[] You have AC wave regulation and you want to reduce some of that alum porosity what do you adjust?

[] Are different wave form patterns something your welds really need?

[] Can you explain why any company any company can decrease it’s TIG weld labor costs by 100 – 400 %, with using the TIP TIG process.

[] Can you explain why in less than 10 days, that it’s possible to train none welding personnel on how to pass any all position, code pipe test, on any alloy or steel application using TIP TIG.

[] Can you explain why regular TIG and Hot Wire TIG are a poor process for many automated or robot TIG welds, and why the TIP TIG process is far superior?

[] Can you explain why in contrast to any TIG weld on any metal, that you will get superior side weld fusion and less porosity from the TIP TIG process.

[] Can you explain with TIP TIG, why you don’t need a gas trailing shield for most Titanium welds >3mm?

[] Can you explain why pre-heat may be reduced or eliminated, and inter pass temp controls reduced with TIP TIG?

[] Can you explain why most advanced electronic options on a new TIG power source are not necessary with most TIP TIG welds.

[] Can you explain why in contrast to TIG or Hot Wire TIG, you always attain superior mechanicals and superior corrosion properties from TIP TIG.

.
For more than six decades, TIG equipment rarely changed. If you examined the global weld specifications and procedures being used in 2017 you will find that the spec / procedures revisions rarely have anything to do with the TIG equip. / process technology available today. It’s ironic that in 2017 as we rush to build space vehicles we will be utilizing data influenced by 1980s weld specifications or procedures that in the last three decades may have been revised with a grammer error.


IT’S TIME TO CHANGE and change starts in the engineering office.

Can you explain the unusual color of this
untouched E309, 7 mm, TIG fillet, and the miniscule HAZ.


In industry where focus is too often on welder skills, where process control expertise and best weld practice discussions are rare, where process – equipment ownership by management is poor, it should be no surprise to find that TIG weld process optimization is not what it should be, and the weld shop culture is “why change the way we have always done it”


WITH THE UNIQUE TIP TIG PROCESS, ELECTRONIC OPTIONS ARE RARELY REQUIRED, THE WELD ENHANCEMENT COMES MOSTLY FROM THE MECHANICAL ACTIONS IN THE WIRE FEEDER. 

Few alloys attain benefit from weld heat, however the process most widely utilized to weld alloys is TIG, a process that due to it’s low deposition, low travel rates usually puts more weld heat into a part than any other weld process. The evolution of TIG, is TIP TIG. This process  will always attain higher weld quality than TIG, and as TIP TIG provides much higher TIG weld speeds, this process provides the least weld heat into any metal being welded.

TIG has been around for 70 years yet even in high tech industries such as Aerospace. Powe, Oil  and Defense, you will find that too many TIG weld procedures utilized are out-dated,  poor and show a lack of TIG weld process control and best weld practice expertise.

For years the increasing TIG Inveter weld process control options have
either added  confusion to the shop or are not mentioned in the weld specs.


At present Ed is assisting UTAS / Boeing / NASA with TIG weld projects that are
will be part of the ORION Space project. (space ship to Mars. One day Ed hopes to get NASA Boeing and Spacex into welding using 21st Century process control methods.

Item 5.
Advanced TIG. Cost $275.00, plus $30 USA & Canada shipping.
Shipping to other countries $60.




Those that purchase my materials can without charge call me any time with weld questions. And yes even tho I’m now an old fart I still do inhouse training, if treated right

Its now Em. 828 337 2695 . Email ecraig@weldreality.com

For those that believe that their experienced, skilled weld personnel, have the Weld Process Controls – Best Weld Practice expertise necessary to always attain optimum, MIG and Flux Cored weld quality & productivity at the lowest weld costs, you may want to try the following fundamental MIG or Flux Cored Weld Test, and consider the importance of the questions.

TEST YOUR MIG WELD EXPERTISE?

Em’s MIG Weld Process Controls & Best Practice Test.

Global Universities, Colleges & Weld Training Facilities, don’t provide the weld industry with the PROCESS CONTROL – BEST PRACTICE training that has been required for decades.

TEST YOUR FLUX CORED WELD EXPERTISE?

Em’s Flux Cored Weld Process Control & Best Weld Practice Test.

Item 1. Full Description of “The Manual MIG Program”.

Manual MIG Welding CDDeveloped for ” Engineers, Technicians, Supervisors, Inspectors and all welders. This program provides the total MIG Weld Process Controls and Best Weld Practices that are necessary to consistently provide the highest weld quality at the lowest possible weld costs. Developed by Ed Craig.

This order contains 3 items, 1 – 1a – 1b.

The “Manual” MIG weld process control program was developed for optimizing all carbon steels, alloy steels, stainless, duplex and aluminum MIG applications on 20 gage to any thickness.

[1] Training Power Point CD: “Manual MIG Best Weld Practices and Process Controls”

[1a] Book: “Manual MIG including Pulsed MIG”

[1b] DVD film: “Manual MIG Process Controls Made Simple”

To Order Click Here.

Description for Item 1.

Robot MIG Welding[1] “Manual” MIG Weld Process Controls & Best Weld Practices Training Program”

This program requires a minimum of 16 hours to present. The person who presents the program requires no expertise on the subjects:

Is it logical to provide welders who likely for years, have played around with their conventional CV MIG equipment with two MIG weld controls, with a new $6000 – $15000 pulsed MIG weld power source, and then ask them what do they think of the new pulsed technology?. Is it logical after the pulsed equipment purchase, for the management again over the next decades to continue to watch those welders “play around” with their pulsed MIG weld controls?

My process controls training program eliminates the need to play around with regular MIG or Pulsed MIG controls.

It has to be frustrating for managers or engineers who believe in a uniform, controlled, best practice approach to manufacturing, to daily watch manual weld personnel deliver inconsistent weld quality and weld productivity results.

My process controls training enables with a group of welders, weld uniformity while delivering optimum weld quality – productivity.

Many weld shops have to daily deal with variables that influence the manual weld quality and productivity. Mill scale changes with each batch of steel. Surface contaminates on the welded parts are common, and poor. inconsistent part fit is a common disease in too many weld shop.

My process control training enables the weld decision maker to instantly set optimum parameter adjustments to compensate for any variable that impacts the weld quality – productivity.

I took > 3000 hours to produce this program which has evolved over three decades and is updated often. Without question this is the most comprehensive, practical and unique Manual MIG Process Control – Best Practices training program ever developed. This manual MIG program provides Best MIG Weld Practices and simplifies Optimum Weld Parameter Selection for all MIG, Short Circuit – MIG Spray – Pulsed MIG STT MIG- RMD MIG- CMT MIG applications.

FACT: After the less than 16 hours required for this presentation, you should expect instant weld quality and productivity improvements and a distinct, uniform approach by all the participants to the welds they daily produce. As this program increases the weld operators confidence in optimizing and controlling the weld transfer modes for any application, you will find this program also dramatically decreases the time required for any new employees to undergo MIG training.

WHY WORRY ABOUT THE SHORTAGE OF MIG WELDERS: Hopefully by now you realize that weld skills have always been only a partial, small requirement for MIG – FCA weld process optimization. Once you provide process control training, which is the missing link for most weld shops, this program will produce instant, impressive results. As for the concern for finding MIG welders please note; You can take a person who has never welded, and with this program and my requirements for 30 to forty hours of hands on training, you should end up with a “professional” MIG welder capable of consistently producing optimum MIG weld quality and productivity on any MIG application.

[] Imagine running a weld shop, in which all the manual MIG weld personnel are aware of the reasons for weld defects, and these individuals have the process control – best Practice expertise necessary to minimize the opportunity for weld defects.

[] Imagine running a weld shop, in which all the weld personnel including supervisors and inspectors have the ability to set the most suitable weld transfer mode and instantly set spatter free, optimum MIG Short Circuit, MIG CMT, MIG RMD, MIG STT, MIG Globular, Pulsed MIG and MIG Spray parameters for any weld, any wire size or type, on any weld application, and do this without looking at a note pad or a computer.

[] Imagine running a weld shop, in which all the weld supervisors, managers, engineers and technicians understand the cost of any weld produced, and all the weld personnel are aware of the optimum MIG settings that will deliver maximum weld deposition rates producing the lowest weld labor costs for any application.

[] Imagine running a weld shop that does not waste money on useless costly electronic MIG equipment, senseless three part gas mixes and those costly metal cored wires. This program shows how the lowest cost MIG equipment and the lowest cost, two part MIG mixes, can meet your all your weld quality and productivity requirements.

WHEN SOMETHING OF GREAT VALUE IN AN INDUSTRY APPEARS TO BE COMPLEX AND POORLY UNDERSTOOD, SOMEONE SHOULD STRIVE TO MAKE IT SIMPLE “.

From one of my weld reports to GM in the 1980s.For decades I worked on the simplification of the world’s most utilized welding processes.

This manual MIG package presents the copy right protected “MIG Weld Clock Method”. I developed this training method over three decades. The MIG Clock Method provides a unique, approach which simplifies the selection of the MIG data to that’s necessary to attain optimum MIG weld quality – productivity on any steels, stainless, alloy steels and aluminum applications.

.

NO MIG WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THIS PROGRAM, AND THANKS TO THE UNIQUE “CLOCK METHOD” SIMPLIFICATION, NO NOTES ARE NECESSARY.

[] This training resource is the only global resource available that provides you with the reasons and logic why you should use the low cost CV MIG equipment and have weld quality concerns when you utilize the more costly Pulsed process, Inverters or Multipurpose welding equipment on all steels and stainless applications > 1/4 (> 6 mm).

[] For those interested in weld consumable cost savings, in contradiction to what your weld sales rep may tell you, this program provides the evidence of why your organization may be wasting money on costly metal cored and flux cored wires and why you should cut back on the gas mixes you use and stop using costly three part gas mixes.

[] The program high lights the root cause of all of your potential weld defects and graphically reveals the instant, practical, cost affective process control resolutions.

The program benefits are many.
[] No more “playing around” with weld controls. Imagine a weld shop that can instantly set the optimum
weld data for any Short Circuit – Spray or Pulsed weld on any weld application.
[] Enables weld personnel to minimize weld rework.
[] Enables weld personnel to create the lowest possible weld labor costs.
[] Weld meetings? No more time wasting, argumentative meetings on weld issues.
[] No need to spend extra dollars on weld equipment loaded with useless bells and whistles.
[] No need for useless, costly 3 part gas mixes or metal cored wires.
[] No more guessing at weld costs. In a few minutes, any weld personnel will be able to tell you the cost of any weld.
[] A weld shop finally unified in it’s approach to attaining optimum weld quality and productivity.

WHEN THIS TRAINING IS PROVIDED TO A COMPANY, ENSURE ALL PERSONNEL INVOLVED WITH WELD DECISIONS, MANAGERS, SUPERVISORS, TECHNICIANS, WELDERS, QA MANAGEMENT AND INSPECTORS ARE INCLUDED.

Robot and Manual MIG Welding Process Control
Item [1a] includes;

“Manual & Robot MIG Weld Process Control Simplification”.

Written by E Craig. (170 pages).

This is a “self teaching” Manual and Robot MIG Weld Process Control, Training book. This book is an essential tool for MIG weld quality / productivity optimization. With this book you will learn Ed’s unique, weld process control “Clock Method” which provides a simple, highly effective, easy to remember approach to the selection of optimum MIG parameters for any manual – robot carbon steels, alloy steels and stainless applications. The information in the 170 pages enables the reader to answer the 160 process control questions provided. This book is the first step to present either the manual MIG or robot process control training programs.

Item 1b. The MIG DVD Video.

“Manual MIG Process Controls Made Simple”.

Produced by Ed Craig. (Run time approx. 60 minutes).

Remember, if a picture is worth a 1000 words, this video is worth a million. This DVD is a great introduction to the Clock Method and the simplification of optimum, CV MIG weld parameter selection. This unique MIG training DVD has been purchased by more than 4000 companies in 14 different countries. Companies such as GM, Caterpillar, Case, Ford, Volvo, Tower Automotive, Magna, Dana, ABB, Babcock, Boeing, Delphi, TRW, Monroe, Johnson Controls, Textron, Genesis, General Dynamics, General Electric and numerous others.

E-mail: Dear Ed. I am a weld engineer working in the UK. I recently discovered your excellent web site and process control training resources. I just wanted to drop you a line to express my thanks for the excellent information. Yours Sincerely. Richard Powell. England.

E-mail: Ed your books and CD’s arrived on Friday. I can see from the couple of hours reading that I’ve done that they’re full of valuable MIG and Flux Cored weld process control and best practice knowledge. The advice is great Ed. Thanks for the wonderful info and the web site. Sincerely. Mike Harris. New Zealand.

Below: ASTEC Industries is America’s leading manufacturer of heavy equipment such as Rock Crushing Equip, Asphalt Road Building – Aggregate Processing equip, Pipeline and Utility Trenching equip. A rock crushing machine can cost over a million dollars and with this product you had better ensure you have no weld failures.

.

ASTEC builds some of the world’s most rugged equipment, and with their rugged products there is simply no room for weld faults or weld failures. To ensure ASTEC could consistently attain obtain optimum weld quality and productivity, ASTEC asked Em to provide MIG – flux cored weld process control – best practice training, and they utilized my MIG and Flux Cored Best Weld Practices – Process Control Manual Training Resources.

Questions call 828 337 2695. E Mail ecraig@weldreality.com

To Order Click Here.

Item 2: Description on Flux Cored Weld Process Control
and Best Weld Practice Training Program.

As a weld decision maker, you would not need the following resource if you
can answer the following fundamental Flux Cored process control questions. 




Em’s Flux Cored Weld Process Control Test.

From Weldreality QA forum. 2/12/2011:
Ed, I have watched your web site “weldreality.com” for several years and finally purchased one of your courses. If a person does MIG – Flux Cored for a living, the info you provide is gold. I was amazed at the solid info-no guessing or playing with the weld control info. The weld forums I frequently visit are full of opinions and “try this or we “played around with the settings” comments…Em your process control – best practice approach is simple and fool proof. I have been doing SMAW / GMAW pipe work for many years and never found anyone who could tell me how to simply set optimum flux cored and MIG weld parameters. Your materials did this in a few hours. I wish I would have found this info years ago.

Thanks Ed.
Regards JB .

Item. 2 contains items 2 – 2a – 2b.

[2] Gas Shielded Flux Cored Training CD. Best Weld Practices and Weld Process Controls”.

[2a] Book: “Gas Metal Arc and Flux Cored Weld Process Controls”

[2b] DVD film: “Manual MIG Process Control Made Simple”

To Order Click Here.


[Item 2] “Gas Shielded Flux Cored Process Controls – Best Weld Practices Power Point Training Program”.

It’s took Ed over 3000 hours to produce this extraordinary Power Point program on Flux Cored Weld Process Controls – Best Weld Practices. This program enables any company to optimize it’s flux cored manual and automated weld applications. As flux cored is a prime process for pipe and vessel welds, also included in the program is MIG Short Circuit, MIG STT and MIG RMD process optimization required for open root welds.


THOSE WELD SHOP PROCEDURES ARE TYPICALLY ONLY
PART OF THE WELD SOLUTION.

API – ASME – AWS – NACE – ABS. All weld codes require optimum flux cored / MIG weld procedures, yet every critical code weld that has had a costly weld repair, or every code weld that failed, was a weld made with a qualified weld procedure.

Gas Shielded flux cored wires are utilized for numerous code weld applications. Understanding the weld shop variables, the required weld shop practices and e process control requirements and the key root causes of the flux cored weld defects, will greatly assist any weld shop in the prevention of those defects.

All weld professional decision should understand the root cause of flux cored weld defects and have the ability to provide the resolutions which will come from weld process control training, and the implementation of best weld practices.


IN MOST LARGE WELD SHOPS, YOU WILL FIND MANY SKILLED, AND EXPERIENCED WELDERS,HOWEVER IT’S RARE TO FIND WELD PERSONNEL WITH FLUX CORED WELD PROCESS CONTROL AND BEST WELD PRACTICE EXPERTISE.

A common denominator found in most weld shops will be most of the welders will “play around” with either their flux cored or MIG weld controls. Also you will find many of the welders using only one wire feed and volt setting for welds on different parts and different thickness.

If you wanted to understand the level of lack of weld process control and best practice expertise at your facility, ask five of your most experienced weld personnel the following five questions. Then watch the response which typically will be five very different and mostly incorrect answers.

YOU HAVE PURCHASED A NEW MIG POWER SOURCE WITH A DIGITAL FEEDER. ASK THE WELDERS TO PROVIDE YOU WITH THE “OPTIMUM WIRE FEED RATE AND VOLTAGE” FOR THAT VERY COMMON, VERTICAL UP, 1/4 FILLET WELD. THE WIRE IS 0.045 (1.2 mm) 71T-1. THE GAS ARGON – 20 OR 25% CO2.

ASK FIVE WELDERS TO DESCRIBE THE FLUX CORED WELD TECHNIQUES NECESSARY FOR A ROOT WELD WITH A CERAMIC BACKING, VERSUS A ROOT WELD WITH STEEL BACKING.

ASK FIVE WELDERS WELDING A COMMON 1/2 GROOVE WELD TO TELL YOU WHERE TO EXPECT THE COMMON FLUX CORED DEFECTS, AND WHAT THEY COULD DO TO MINIMIZE THE OPPORTUNITY FOR THOSE WELD DEFECTS TO OCCUR.

ASK FIVE WELDERS TO TELL YOU WHAT PARAMETER THEY WILL HAVE TO CHANGE, (AND WHY), IF THE E71T-1 FLUX CORED WELD GAS IS SWITCHED FROM STRAIGHT CO2 TO ARGON – 25% CO2,

ASK FIVE WELDERS WHAT THOSE WELD WORM TRACKS ARE, AND HOW THEY CAN MINIMIZE THEM.

ASK FIVE WELDERS WHAT PRAMETERS THEY WOULD CHNAGE IF THEIR WELDS WERE PRODUCING ERRATIC, GLOBULAR TRANSFER WITH EXCESS WELD SPATTER. AND WITH THE SILENCE THAT WILL LIKELY BE PRODUCED, YOU WILL DECIDE IT’S TIME FOR A BREAK.

FUNDAMENTAL FLUX CORED WELD PROCESS QUESTIONS AT Ed’s Flux Cored Weld Process Control Test.


IT’S A GLOBAL CONCERN. EVERY WORKING DAY, THE WELD INDUSTRY LOOSES HUNDREDS OF MILLIONS OF DOLLARS FROM UNNECESSARY FLUX CORED WELD REPAIRS & REJECTS, AND ALSO FROM POOR WELD PRODUCTIVITY FROM POORLY UNDERSTOOD WELD PROCESSES.


NDT TO EVALUATE THE INTERNAL WELD QUALITY IS TYPICALLY APPLIED TO < 3% OF FLUX CORED WELDS.

THE DAILY WELD REALITY: WITH THE GREAT MAJORITY OF FLUX CORED WELDS IF INTERNAL WELD EVALUATION WAS APPLIED , THE WELDS WOULD REVEAL UNNACEPTABLE LACK OF FUSION, EXCESS SLAG AND POROSITY. WHILE NOT REVEALED, THESE DEFECTS COULD AFFECT THE FUTURE INTEGRITY OF THE WELDED PARTS PRODUCED. 
THE FLUX CORED WELD QUALITY ISSUES ARE PARTIALLY FROM THE WELDER’S SKILLS, BUT MOSTLY, FROM THE WELD SHOP’S LACK OF WELD PROCESS CONTROLS AND BEST WELD PRACTICE EXPERTISE.

MANAGEMENT RESPONSE TO WELDING VARIABLES: A walk through any weld shop would instantly reveal that it would be beneficial if the weld personnel were trained to provide the correct response to the many variables that daily affect the weld quality – productivity.

MANAGEMENT RESPONSE TO WELDING VARIABLES: A question any good, weld shop engineer, manager or supervisor should ask, is how well will our weld personnel respond to flux cored welds that will be on parts that are undersize, parts that have excess gaps, parts with weld joint misalignment, parts with poor weld edge preparations, parts with poor weld joint access, parts with difficult out of position welds, parts with unacceptable surfaces, or parts welded in changing environments.

MANAGEMENT RESPONSE TO WELDING VARIABLES: An engineer, supervisor, technician or welder, cannot provide the correct respond to weld variables, if they have to “play around” with weld data, or they have to get weld advice from a weld salesman. All weld decision makers should have the ability to instantly provide flux cored parameter adjustments – best weld practices that will provide the correct resolutions to the variables.

IT MAKES NO SENSE TO PURCHASE THE BEST WELD EQUIPMENT AND CONSUMABLES IF THE WELD SHOP PERSONNEL LACK THE ABILITY TO CONSISTENTLY ATTAIN THE HIGHEST POSSIBLE WELD QUALITY AND PRODUCTIVITY,

Apart from working in a safe environment, the most important role of weld shop management, engineers, supervisors and technicians, is to ensure the welders daily get the best possible weld quality – productivity from the weld equipment – consumables purchased. As many of you will be aware, most MIG – FCA weld personnel will too often not be using optimum weld settings, and most welders will be using inappropriate practices, incorrect self taught weld techniques, or using the weld techniques taught by a weld instructors that is much more comfortable teaching the SMAW (stick) process.

MANAGERS AND THOSE WELD COSTS: Managers and supervisors, you cannot control weld costs unless you understand the wire feed requirements and weld deposition rate potential relationship of what you should be attaining with the common wire sizes utilized on your common welds. The highest weld profits attained in any weld shop are derived when that shop consistently attains the highest possible weld quality with the highest possible weld deposition rates. My resource simplify this complex subject so all that is necessary is a glance at the consumable and the wire feed control.

TEACH YOUR SELF, OR TEACH A GROUP OF WELD PERSONNEL IN A CLASSROOM. THIS UNIQUE, ANIMATED, POWER POINT PROGRAM WILL REQUIRE APPROX. 14 – 16 HOURS. AS WITH ALL OF MY PROCESS CONTROL PROGRAMS, NO WELD PROCESS EXPERTISE IS REQUIRED FOR THE PERSON WHO WILL PRESENT THIS PROGRAM OR MY MIG PROGRAMS.

This unique program provides everything your workforce could possibly ever need to know about optimizing manual / automated Flux Cored, (also MIG root) weld quality and productivity on all position pipe, plate, structural and pressure vessel welds.

The flux cored weld wires covered. EX1T-1, EX0T-1, l carbon steels, plus all low alloy and all stainless wires. Wire Sizes covered. 0.045 – 0.052 – 1/16 – 3/32, (1.2 – 1.4 – 1.6 – 2.4 mm). From optimizing a ship’s plate weld with ceramic backing, welding construction equipment with steel backing. It covers the requirements for welding the most complex pressure vessel and pipe applications. A few hours with this resource and your weld personnel will have the ability to instantly provide optimum flux cored weld data and techniques that will always ensure minimum weld defects, with maximum weld productivity.

Weld benefits generate weld cost savings.

[] A professional weld shop in which weld personnel no longer “play around ” with weld controls. The welder sees an issue that effects the weld quality and productivity and instantly provides optimum data and techniques necessary to resolve that issue.

[] No more welders utilizing “stick weld techniques” for flux cored welds which require specific techniques for all position applications.

[] Weld personnel with the best practice expertise necessary to deal with the daily application variables and conditions that influence many flux cored welds. Variables such as mill scale, rust, surface contaminates, excess or tight gaps and poor edge preparations. Variables that lead to common flux cored weld defects such as lack of weld fusion, weld cracks, porosity, worm tracks, slag inclusions and spatter.

[] All weld personnel being aware of the flux cored fine tuning parameter requirements necessary for applications, especially those welds with different wire stick out requirements as found with different thickness groove weld joints.

[] For the weld position used each flux core wire size has has two optimum wire feed and voltage settings. Every weld decision maker should know those settings.

[] All weld personnel being aware of the unique process / technique requirements for flux cored welding root gaps with steel, copper and
ceramic backing which requires unique weld considerations.

[] Single and multi pass fillets. All position groove root, hot pass, fill pass and cap pass welds. All of these welds have unique process and technique requirement which are presented in this program.

[] As open pipe roots welds are common welds in flux cored shops, this training CD also provides the MIG weld data and techniques necessary to instantly set optimum, all position MIG root welds with the short circuit, STT, RMD processes.

[] Weld equipment and weld consumable data that you will never get from a salesman.

The CD presents the training program in a simple unique manner, in which without taking notes, weld personnel will remember optimum weld settings for any application.

The results from this easy to present, approx eight hour, flux cored classroom program will be immediate, then follow up with Em;s recommended hands on technique training recommendations which require four hours “hands on” and that’s it. When your employees are trained, the participants will have a uniform, logical, consistent process control approach to dealing with weld issues and variables that daily impact all weld applications. As Ed is always focused on weld costs, you can be sure these weld recommendations ensure optimum weld deposition rates are always attained, dramatically improving your daily weld production

OPTIMUM CODE QUALITY WELDS NEED OPTIMUM WELD PROCEDURES WHICH NEED OPTIMUM WELD DATA AND BEST WELD PRACTICES:

Welding ships, trains, pipe lines, oil platforms, refineries, construction projects heavy equipment, bridges or cranes, there is no better weld data provided than the data in this program.

THIS PROGRAM WILL DRAMATICALLY REDUCE BOTH THE TYPICAL WELD TRAINING TIMES AND THE WELD TRAINING COSTS: 

For those that spend weeks or months training personnel, take note. With this class room process control resource, I guarantee that you can take a none weld person and with one day in the classroom with this CD program and then provide three days hands on. That person should be able to produce flux cored welds that will meet any code requirement for any position welds.

YOU CANNOT CREATE AN EFFECTIVE WELD TEAM WITHOUT A UNIFORM APPROACH TO THE WELDS PRODUCED. YOU WILL NOT PRODUCE OPTIMUM, CONSISTENT QUALITY WELDS AT THE LOWEST COSTS, WITHOUT THE IMPLIMENTATION OF BEST WELD PRACTICES AND WELD PROCESS CONTROLS.



Em provided flux cored best weld practices and process control training for all the weld personnel including supervisors, engineers and managers at the Aker Kavverner ship yard located in Navy Yard. Philadelphia, PA.



This program encourages the weld team approach to weld process optimization. All industries are aware of the liability consequences and costs associated with flux cored failed welds, weld rework and poor productivity. This training is applicable to anyone in a plant who welds, or makes decisions on flux cored weld quality or productivity. To be part of the team, managers, engineers, supervisors, QA personnel and of course all weld personnel should walk the same process control path to weld process optimization.

Note: For those that think they already have trained employees, try the following weld test. If you are a welder ready to take a flux cored weld test, or an engineer, supervisor, technician or manager who wants to improve your career prospects, it’s logical that you should fully understand the process you intend to manage and control.



Item 2a includes. Th
e Book. ” GMAW and Flux Cored Weld Parameters”.
Written by Ed Craig. (156 pages).

MIG and Flux Cored are the two most utilized weld processes, yet, for over 30 years, lack of focus on process control training has retarded the growth of these two important weld processes and contributed to a global industry in which too many weld personnel “play around” with their weld controls. The general lack of process expertise and extensive reliance on sales advice, daily impacts both MIG and flux cored weld quality and costs. Unnecessary poor weld quality, unnecessary weld rework, unnecessary low weld deposition rates, a general lack of understanding of real world weld costs and the purchase of incorrect weld equipment and consumables are common in many weld shops.

This weld process control book provides in-depth process control – best practice weld data for both Gas Shielded Flux Cored and MIG. No more “playing around” with the MIG and flux cored weld data. MIG and flux cored manual weld parameter selection is made simple with Ed’s unique “Weld Clock Control Method”. The weld data provided applies for all manual carbon steels, low alloy steels and stainless applications.

Flux Cored Pipe Welding

Ed provided flux cored training, using his easy to remember clock method,
for Canada’s largest Oil / pipe line company and for several ship yards.


E-Mail:

Dear Ed,
I am a welder living and working in Australia. I found your web site and am very interested in your books. “Manual “Gas Metal Arc & Flux Cored Welding Parameters“. I am currently undertaking a diploma course in welding technology and while I can learn untold amounts about welding theory and how the materials change etc., I have yet to find any instructor or welder in the industry that knows how to simply set up a GMAW machine properly. Most people I have met just play around with with their MIG or flux cored weld settings and focus on the skills required. For many weld personnel, if the weld looks good, that’s enough, however it’s not good enough for me. I want to know the optimum weld settings for any application and I certainly don’t want to play around with weld controls.

Yours sincerely
I C Ormrod

In the weld shops where many welders will use their weld skills to compensate for their lack of weld process control – best practice expertise, it’s common to see weld personnel “playing with the MIG or flux cored weld controls”.

If you are a professional in the welding business, you should know instantly where to set the wire feed and voltage controls for the common MIG and flux cored weld consumables and weld transfer modes.


Many weld shops have manual pipe and structural welders who daily 

use inappropriate SMAW (stick) weld techniques on their MIG and flux cored welds.

This book provides the optimum weld settings they should be using and if you want to provide your weld personnel with the world’s most comprehensive process control training program, take a look at



Ed‘s flucored training program saved Aker Kaverner (builds oil tankers) at the Philadelphia Naval Ship Yardover 5 million dollars annually through less E71T-1 flux cored weld rework and a dramatic increase in weld production. This training resource will benefit any weld decision-maker, trainer, or quality control personnel that’s interested in manual FCAW weld process optimization.


E Mail from Steve.

Ed: Just found your site and I am slowly going through it. I hope you enjoy doing this, because it sure is a great asset to the weld industry. I’m a retired pipe welder, and now teach welding. I have some experience welding with MIG and gas shielded flux cored wires, but I’m weak with weld parameter selection. I’m ordering your book tomorrow. Would it be all right if I asked you some questions (after I read the book) so I can enlighten my trainees. In the past when I have had weld technical questions, I have tried both Miller and Lincoln technicians, but either get answers that make no sense or no answers. Regard
less, great job on this site. Steve. Bleile wallmountain@imbris.net

[Item 2b] The DVD MIG Video

“Manual MIG Weld Process Controls Made Simple”.

Produced by E Craig. (Runs 60 minutes).

If a picture is worth a 1000 words, this video is worth a million. This DVD movie is a great visual tool in presenting my Weld Clock Method, which simplifies optimum MIG Parameter Selection for any steels alloy steels and all stainless applications, The clock method is also used to simplify flux cored weld settings. This video has been purchased by more than 4000 companies in 15 countries. Companies such as GM, Caterpillar, Case, Ford, Volvo, Tower Automotive, Magna, Dana, ABB, Babcock, Boeing, Delphi, TRW, Monroe, Johnson Controls, Textron, Genesis, General Dynamics, General Electric and numerous others. Note: 

E-Mail.
Dear Ed. I am a welder living and working in Australia. I am currently undertaking a diploma course in welding technology and while I can learn untold amounts about welding theory and how the metals are different etc., I am yet to find any instructor or welder in the industry that knows how to simply set up a GMAW machine for optimum MIG and flux cored welds. Most people just play with the weld controls, if the weld looks good that is enough for them, but that’s not good enough for me. I want to know how to control the process and achieve maximum weld deposition rates. Em thanks for the great web site and thanks for your very unique weld process control training resources.
Regards. I C Ormrod. Australia.


E-Mail.
Hi Ed. I Just wanted to say thanks for the MIG and flux weld book, the weld process control advice in it is priceless. Thanks a Million. Dave Helliwell. djhelliweld@hotmail.com

E-Mail.
Dear Mr. Ed. I have been welding for ten years but have never, like you say really known the proper weld parameter settings. A few hours with your materials and now I can instantly set optimum manual MIG and flux cored weld parameters for any application. Thanks for your help and great web site. Sincerely. Larry Fritsche.

E-Mail.
Good day Em. I found your Flux Cored Welding book an excellent weld process control training resource. Chris Stask. Weld Instructor. Camosun College.Vancouver Island BC.

E-Mail.
Dear Ed. Your training resources and web site have been very useful to me . I admire you for your knowledge in welding. If you visit Saudi Arabia please contact me. I am eager to meet you. With great respect and regards. B. Muralidaran. Saudi Arabia.

Item 3 Robot MIG Weld Process Controls and Best Weld Practice Resource:

To Order Click Here.

Ed developed 7 Steps to Robot Weld Process Controls. With this unique program you can do what he did at numerous global companies. Make one robot produce the same weld production that’s typically attained by most companies that use two robots, and make all the robots attain their maximum weld quality potential.


Above. Em set these Merced es Car Seat Robot Welds in Spain.

When an organization has MIG robots, they often will have a QA team. The question is what real value does the inspection team offer if they only find weld issues after they occur?

In most weld departments, inspection personnel will have received some training in finding and figuring out weld defects. I don’t think in the 1000 companies that I visited, that I met one QA department manager who had ensured his weld Inspectors were trained with the process control expertise that would help the prevention of weld defects. , Imagine how cost effective this approach would be for a company in which weld inspectors primary role, would be to prevent the weld defects rather than just find them.

As many of you are aware, in the global auto – truck industry, the only weld process optimization that comes from controls and best practices seems to occur in the paint department. In contrast you will typically find the daily robot, MIG and resistance weld quality and production often leaves much to be desired. With the auto – truck industry (where the majority of robots are purchased), and industry that spends billions each year on recalls that come from ineffective engineering management, extensive robot weld rejects and rework with unacceptable robot down time is considered normal.

For those managers and engineers that are not satisfied with their weld manufacturing results, and are ready to implement changes for their robot MIG welds, Item. 2. (following) will provide a great opportunity for weld quality – productivity improvements, and of course ensure dramatic weld cost savings:

ROBOT WELD FACTS RARELY DISCUSSED IN THE GLOBAL AUTO INDUSTRY…

[a] The average Robot MIG Weld Production Efficiency is approx. only 40 – 60% of it’s full weld production potential.

[b] The average Robot Weld Rework is typically in the range of 10 to 60%.

[c] If macro examination, or any internal weld evaluation was required on auto – truck robot welds, I out of every three of the robot welds that are at this time accepted, would be rejected due to fusion – undercut – porosity issues..

[d] The average Robot Down Time per-eight hour shift is approx. 30 – 45 minutes.

[e] The majority of manufacturing companies that have purchased MIG welding robots, have never attained the full weld quality and production potential from their robots. Its a sad point to state, but for the last 20 plus years, most of the managers, engineers, supervisors and technicians involved with the MIG welding robots are simply not aware of the robot MIG weld production potential of each robot cell.

[f] The majority of global companies using MIG welding robots, do not have personnel qualified to establish Best Robot Weld Process Controls or Best Weld Practices. The bottom line for more than two decades, the majority of persons that make the robot weld changes each shift, have typically not been qualified to make those weld changes.

[g] There are few plants in which you will find a manufacturing manager, engineers or weld supervisor that can in a few minutes provide you with the real world cost per foot of their most common, robot MIG 3/16 or 1/4 (5 – 6 mm) fillet weld.

[h] More and more welded parts have galvanized or galvanealed coatings. My program provides 10 very effective solutions to reducing the weld porosity, spatter and weld cracks that occur with zinc coatings. With these solutions you don’t need personnel “playing around” with the weld controls and workers doing repairs.

WHEN PROCESS EXPERTISE IS THE MISSING LINK: Many robot MIG applications are initially set by the integrators who sold the robots. The integrator personnel typically will have extensive robot cell build and “programming expertise”, however the employees who establish the welds, will generally lack the MIG, Robot, Weld Process Control and Best Practices expertise. Once these robot cells are delivered, they are too often managed again by personnel who again can operate the robots, but have never received MIG process control training. In these circumstances, it’s understandable that the robots rarely attain their full production and quality potential.

YOU WOULD THINK ANY MANAGER OR ENGINEER, WOULD WANT HIS FACILITY TO BE ABLE TO FULLY CONTROL BOTH THE COSTLY ROBOT EQUIPMENT, AND THE WELD PROCESSES THAT THEY PURCHASED:

Adding to the typical plant’s poor robot weld efficiency, less than optimum weld quality and unnecessary weld costs, is the vast majority of manufacturing managers – engineers who decide which robots and weld equipment to purchase, lack the process expertise necessary to implement robot weld quality and production optimization.

THE MAJORITY OF GLOBAL MIG WELDING ROBOTS UNDERACHIEVE ON THEIR FIRST DAY ON THE JOB,THEN THANKS TO THE UNDER QUALIFIED PERSONNEL THAT DAILY MAKE THE ROBOT CELL WELD CHANGES, THE ROBOT WELD QUALITY – PRODUCTIVITY TYPICALLY REMAINS STAGNANT OR DECLINES.

GLOBAL ROBOT MIG WELD FACT: It’s a reality that the majority of companies who have purchased two or more robots for MIG welds, could with weld process control knowledge produce the same weld production with 30 to 50% less robots.

GLOBAL ROBOT MIG WELD FACTS: The daily logged “Robot Down Time” in many plants is often mostly management fiction, and those manual MIG welders doing the robot weld rework are too often considered by the process ignorant management, as an acceptable part of the costs for the robot welded parts.

GLOBAL ROBOT MIG WELD FACT: In too many plants, once the new robots are installed, unqualified robot weld personnel will daily make unqualified weld process changes to welds that were supposed to be pre-qualified. Lawyers involved in cars and truck crashes should love this liability fact of auto – truck manufacturing.

GLOBAL ROBOT MIG WELD FACTS: The daily never ending weld changes that occur in too many robot MIG weld cells, rarely resolve the daily weld issues and typically add to the weld rework or production problems. In this situation, robot weld production and weld quality usually erodes. For those of you happy with your car or truck robot MIG welds, it’s important to note that few robot welds have internal weld evaluation. If all the welds in plant that utilized robots were looked at internally, it’s my guess, that most plants would have to stop making robot welded parts.

GLOBAL ROBOT MIG WELD FACT: You can count on your fingers and toes the number of global weld personnel that make robot weld decisions and will have the ability to instantly set an optimum pulsed MIG – Short Circuit or Spray weld with any MIG consumables. With this expertise (which is part of this program), robot personnel will have three unique weld transfer modes that allow them to instantly provide a solution to any weld issue, and the ability to instantly optimize the weld quality and productivity with any automated weld or clad weld.

From robot MIG welds in a car or truck plant to robot MIG welds on spent fuel containers for the Nuclear industry. From carbon steels to alloy steels or aluminum. From automated pipe welds to clad welds, this program enables rapid robot weld quality and productivity optimization.

Item 3.

Robot MIG Weld Process Controls and Best Weld Practice Program.

Three items. Item 3 – 3a – 3b.
To Order Click Here.

Description of Item 3: I developed this Power Point self teaching – training program over two decades. This program took me approx. 3000 hours to produce and its been updated annually. As a training program It will take approx. 14 – 18 classroom training hours to present. For those that do the training, please note, “no robot or MIG weld process control – best practice expertise” is required to present this program.

Irrespective of the carbon steels, low alloy steels, stainless or aluminum, robot applications being welded, this program deals with all the Robot MIG Weld Process Controls – Best Robot Weld Practices necessary to consistently attain optimum robot weld quality and productivity. The program also deals with the primary root causes and resolutions for Robot Down Time, along with the cause and solutions for most Robot Weld Defects. If you have a problem that impacts your robot weld quality – productivity you can call a team meeting and deal with frustration of no one instantly getting to the root cause. Or
you can provide all those involved with robot weld decisions with this resource, and after the training is complete, all on that robot team will walk a single path to instantly resolving those robot MIG weld quality – productivity issues.

PLEASE NOTE. AS WITH ALL MY TRAINING MATERIALS, THE FIRST THING I DO IS” SIMPLIFY THE RESOURCE” SO THAT NO WELD PROCESS CONTROL EXPERTISE IS REQUIRED TO PRESENT THIS PROGRAM TO OTHER PEOPLE.

Please note. I have assisted over a 1000 companies in 13 countries with their weld issues. With the plants that had robot weld issues, I was requested to come to these companies because the major MIG weld equip manufactures such as Lincoln – Miller – Hobart – Panasonic and Motoman, or the major robot integrators and robot manufactures, ABB – Panasonic – Motorman – Fanuc – Cloos – OTC, could not resolve the daily robot weld quality or productivity issues that were being generated by their new robot MIG cells. Typically at these frustrated robot customers, I would quickly reset the robot and weld data, and if requested, I would provide the process control training program (provided here). This program has the information that can enable any plant to consistently attain optimum robot weld quality and productivity.

MANAGERS NOTE: Some managers especially at the major auto companies and there suppliers, actually believe that when they send their operators to go for robot weld training, they were getting the training necessary that enables optimum, robot, MIG weld quality – productivity. Operating a robot is a low skill set, while in contrast programing a robot is a very high skill. Please note, that robot MIG weld process control – best practice training is a completely separate function from robot programming training requirements.

This Robot Weld Process Controls – Best Weld Practice program should be presented to all those weld decision makers that make decisions on the robot welds, and especially those individuals that make the robot weld changes

E-Mail.
Jan 2007: Ed. I wanted to send update about that
E-Town DANA plant that you visited a few years ago:

As you know on your first visit to this plant, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour and over 90% required extensive weld rework.

Thanks to your Robot Weld Process Control Training program and your weld process and consumable changes, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks! Ryan Good: A Grateful Engineer and a grateful DANA Corporation.

Note The DANA corporation is a tier one supplier and world leader in the supply of drive line products (axles, drive shafts, and transmissions) and power technologies for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.

E-Mail: Hello Ed. In the past I purchased your MIG welding training resources for both Caterpillar and more recently purchased your Robotic MIG training package for Elgin Sweeper Company here in Illinois. Ed your programs worked wonderfully at Caterpillar. We were very successful after implementing your Best Weld Practices and Process Control Training. Thanks to your resources and equipment and consumable recommendations, our manual and robot MIG weld quality – productivity results are now outstanding. All the best. Joe Cukierski…Weld Manufacturing Engineer.
Elgin Sweeper Company.

It’s questions like this that get resolved with these resources. “With our robots, we have quite a few wire burn backs to the contact tips and these disrupt production. What parameters or practices do I make to resolve burn backs?

Ed established the original robot MIG Process Control data and Best MIG Weld Practices for the robot MIG welds on the world’s largest trucks.

E-Mail.
Ed as you know Tenneco has plants all over the world. We and especially Monroe Shocks which is one of our companies have been very enlightened by your ” Robot MIG Weld Process Control Training Resources.

Regards. Tom Plummer: Tenneco. USA. 2007.

E-mail. Hello Ed, I wanted you to know I have just announced that I am leaving my company. I am now working for a “robot weld integrator”. I will be the head of the welding applications department and will be specifying process, consumables, training, etc. I am very very excited about this opportunity to learn more about welding and to help others to see the light. I hope that we can stay in contact as the years go on. Most importantly, I just want to thank you for the great weld process control information in your books – CDs and your welding passion which you passed on to me.

Warmest Regards. Jeff Winter. Ont. Canada.


OPTIMUM ROBOT MIG WELD QUALITY& PRODUCTIVITY FOR THIN GAUGE PARTS:

From a product liability perspective, it’s ironic that the majority of so called visually acceptable, robot MIG welds, would with an internal, macro weld evaluation, reveal lack of weld fusion or other internal, unacceptable weld defects.

When robot welding thin gage applications, avoiding weld burn through, minimizing distortion and attaining consistent weld fusion with small weld lengths are common issues.

This one of a kind robot weld process control training program provides instant resolutions to all the primary root causes of unacceptable weld quality, weld rework and robot down time.

When robot welding thin gage welds, you can utilize six common weld transfer modes, MIG RMD – MIG CMT – MIG Short Circuit – MIG Globular – MIG Low Spray, or MIG Pulsed. Every time a weld issue occur with one of the weld transfer modes, their is usually a a rework price to pay and a slow or incorrect process action by those involved. Using my program, an organization avoids weld process issues and they will not have personnel “playing around” with the weld data.

OPTIMUM ROBOT MIG DATA FOR PARTS > 3/16 > 5mm.

When Em was asked to establish the robot MIG weld data for the world’s largest trucks, an application that had welds on parts 1/8 to 8 inch thick, he astounded the robot weld engineers when he said “all the welds could be made with three simple settings”.

Keeping robot weld data to a minimum and developing programs that are simple is easy when you know the optimum data necessary for the application, metal. consumables and weld transfer mode.

A few hours with this unique CD program, and your robot weld personnel will have the ability to;

[a] deliver consistent, acceptable weld fusion and weld quality for any application,
[b] provide weld settings that ensure the highest possible weld deposition rates delivering
the fastest possible robot weld speeds.
[c] eliminate robot and weld issues that cause robot down time,
[d] enable the issues responsible for robot weld rework,
[e] provide instant resolutions to all the primary variables that daily impact the robot weld quality or production,
[f] with the implementation of robot best practices – process controls, create a uniform weld shop environment that enables the lowest weld costs and reduces the product liability concerns.
[g] Know when to switch from Pulsed to Short Circ or Spray and provide settings that ensure the highest possible weld quality and productivity.

Ed set the world’s first, multi-robot cell “MIG weld aluminum frame” application. And created millions in annual weld cost savings in this ship yard.

Ed (photo) set the robot, aluminum frame MIG welds on the golf cart(photo) he used to drive around the Aker ship yard where he was the ship yard weld manager. In this Philadelphia ship yard, Ed taught the welders how to optimize their manual – auto flux cored welds used to build Oil Tankers. The annual weld cost savings that he created per oil tanker, was over 6 million dollars.

A FUNDAMENTAL POINT ABOUT MIG PROCESS EXPERTISE. There is a great value to weld process control and best practice knowledge, especially in an organization that annually makes millions of dollars from its welded parts?

The following may be a stupid question that I should not have to ask, yet it’s a question many managers, engineers and supervisors give minimum consideration to. The following MIG weld process control questions should show you there is value in weld process expertise.

If you are a weld manager, engineer, supervisor or technician, and you asked your most experienced robot and weld decision makers the fundamental weld process questions, (link below). And the weld personnel were not aware of the corrects answers, you may want to ask your self this.

“Why has my company invested thousands or millions in robot weld cells and fixtures and we have not provided our employees with the necessary robot weld process control – best practice training”?

It’s questions like this that get resolved with these resources.”Ed, most of our robot short circuit and pulsed MIG welds are only 1 to 2 inch (25 – 50mm) in length. After weld macro examinations, we find either lack of fusion or poor fusion in the first 12 to 15 mm of the short welds. What robot weld changes can we make to improve the integrity of the weld starts”?

MIG ACCOUNTS FOR 80% OF THE GLOBAL WELDS PRODUCED DAILY:
For those of you that wonder about the level of their MIG weld process knowledge, try this. Ed’s MIG Weld Test.

It’s questions like this that get resolved with these resources. “We have many robot arc start issues, and there is a ball of metal on the wire tip at the weld ends. What adjustments can i change to solve this problem”?

ROBOTS ENABLE FASTER WELD SPEEDS THAN THAT POSSIBLE BY A MANUAL WELDER, YET MAXIMUM WELD SPEEDS WILL RARELY BE ATTAINED WITHOUT THE PROGRAMMER HAVING WELD PROCESS CONTROL – BEST PRACTICE EXPERTISE.

I was the first person in North America to develop extraordinary MIG weld deposition rates of 15 – 25 lb/hr for common MIG gage and heavy wall robot and automated applications. I included the unique high dep weld data in my Management Engineers Guide to MIG, (item 1). Higher MIG depositions enable dramatic increases in robot weld speeds on gage parts and create much lower weld costs on thicker parts. I also developed a patent for MIG high deposition, Cu – Ceramic CONTACT TIPS that were designed for increased robot – automated weld speeds in the range of 60 – 100 inch/min on gage parts. For the power industry, I developed a high deposition, (15 – 20 lb/hr) pulsed MIG patent for inconel / stainless, single pass, clad welds on global water wall boilers.


INSTANT ROBOT WELD BENEFITS:
It’ this simple, bring all your weld decision makers to a training room. Place my CD power point program in a laptop. Project the program to the screen. In a few hours everyone has the necessary robot MIG data to establish Best Weld Practices and implement Weld Process Controls.

As the Genie and Sky Trak plants found out with their lifting equipment, (shown right), with Ed’s manual and robot process control training programs, optimum MIG weld results were immediate and the weld cost benefits were extensive.

THIS PROGRAM ALSO CUTS THROUGH THE TOO COMMON GLOBAL BS AND MYTHS THAT DAILY INFLUENCE THE CHOICE OF ROBOTS, WELD EQUIPMENT AND CONSUMABLES. IT’S ESPECIALLY BENEFICIAL, IF YOU WANT TO GET AWAY FROM THE PURCHASE OF THE OVERPRICED, EQUIPMENT WITH USELESS, ELECTRONIC BELLS AND WHISTLES, THOSE RIDICULOUS THREE PART GAS MIXES, AND THE COSTLY, UNNECESSARY CONSUMABLES THAT ARE PART OF MANY WELD SHOP.

It’s questions like this one that get resolved with these resources.

Our robot, pulsed gauge welds are only 2 to 3 inch (50 to 75 mm) in length. The problem is the last 5/8 to 3/4, (15 to 18 mm) of each weld length. The welds typically get narrower with a crater appearance. What can I do to change the robot data to resolve this?

Ed in a robot cell demonstrating how useless the Miller weld equipment bells and whistles were to the employees at VIZA. This company is located in a town called Vigo in Spain. Viza is one of the largest car seat manufactures in Europe.

At Viza, Ed was hired to optimize the robot weld quality – productivity. In the photo on the left Ed was educating their managers / engineers on what a waste of time and money it was to purchase the the so called sophisticated, Miller Axcess Power source with it’s Palm Pilot Parameter Controls, (shown in photo)… Viza made car seats for Mercedes, VW and Citroen.

Years previously at Viza Ed was asked to select the robots and weld equipment to get Viza into the automation age. He recommended they purchase the less costly, superior performing Miller Delta Weld equipment and ABB robots. With this equipment and with Ed’s Robot Process Control – Best Practice Training Program, Viza had the keys necessary to provide the highest possible weld quality with the desired production at the lowest possible weld costs. Viza grew rapidly into an outstanding European tier one car seat supplier. .

The robot process control – best practice training program which was given to VIZA robot team, is applicable to anyone in a plant who has an opinion or makes decisions on robot weld quality or productivity. Managers, engineers, supervisors, maintenance, QA personnel, robot technicians and operators who make weld changes, all should walk the same path to robot weld process optimization.

Note: If you have robot programming expertise and would like to move forward in your career, pick up this CD, learn the contents and with great confidence you will know you are ready to establish optimum weld automation with any global company on any robot application.

It’s questions like this that get resolved with these resources.

“With our pulsed robot welds, we are getting spatter. When I adjust the pulsed trim voltage to it’s maximum positions on the robot console, nothing seems to resolve the weld spatter. Any robot parameter advice that will minimize the pulsed spatter”?

Ed set the most critical robot TIG welds on the top of the
heating tower on the world’s largest solar project


Photo from Smithsonian Magazine.

One of Ed’s major robot TIG projects, were complex robot TIG welds on the critical components for world’s largest solar farm. the Ivanpah project. These welds were the robot brkt – tube welds, (tower collector vessel welds that receives the rays). These were complex alloy welds on thin parts. The 3500 acre solar farm will produce approx. 392 megawatts. This project cost more than 2.2 billion dollars. The farm has approx. 173,000 mirrors and each 70 sq/ft mirror reflects the sun to a focal collector point on the tower shown. The suns energy will create enough power for 140,000 California homes.

The brkt welds that hold the collector vessels that absorb all that sun’s energy were very difficult robot TIG welds made with extraordinary weld quality demands. The demands were made unnecessary complex by designers, engineers and managers who did not understand weld processes and robot welds. Ed provided most of the weld process controls and best practices that were necessary to overcome the weld complexities on these critical welds.

It’s questions like this that get resolved with these resources.

Ed, we keep getting concave craters at the robot weld ends, and sometimes the
craters have small cracks. What robot weld parameters or techniques can we do to fix this.

I love reading historical fiction about the religious wars that occurred over the last 2000 years between the Muslins and the Christians. My question today is a simple one, with all the issues in the middle east, what the hell has happened to human evolution? And then of course my next question would be, “what the hell has happened to weld shop evolution? .. E Craig. 2013.

Ed, with the robot weld data we use, many of the welds are fine, however we do get quite a few welds that burn through. What robot best practices can i use to minimize weld burn through?

Ed, most of our gauge robot MIG welds are done at weld speeds between 30 – 50 inch/min (75 – 125 cm/min).
My boss was asking if there was any way to to speed up these welds. He wants 20 – 25% more weld production each shift

It’s questions like this that will get resolved with these process control – best practice self teaching – training resources.

Ed’s Robot Process Control programs have been used on Volvo Truck Cabs, Harley Bike frames- Indian bike parts, Corvette bodies, Ford F-150 trucks and much more.

E-Mail.
Ed. I just received your process control materials and within five minutes of skimming through your materials I found flaws in our exhaust weld shop practices and techniques. We were not using logical process controls and your materials will be very helpful to our organization! Ed thanks for sharing your expertise and the prompt delivery of the materials.

Marcus di Sabella. Process Engineer.
Car Sound Exhaust System, Inc. – Magnaflow.
Performance Exhaust. Rancho Santa Margarita, CA.

E-Mail.
Ed. Your process control training resources are fantastic for anybody engaged in weld engineering. They are simply priceless and I am committed to learn them in totality and applying the process knowledge successfully. I shall owe my success to you forever. In case you come out with something new kindly let us know. Thank you very much. Sudip K Haldar. Pari Robots. India.

E-mail. Ed. I work as manufacturing engineer in Johnson Controls Alagon (Spain). We mainly build car seat structures, I believe you set the Johnson control VW Beetle car seats in Mexico and the results were outstanding. Last week I received your robot process control material, which I’ve been reviewing. I find it your program very cost effective and practical. Your approach to weld process control is unique and it certainly works. In reading your materials, it seems like you have been in our company as most of the issues you address and resolve are part of our every day work. Thank you Jose Ignacio Moreno. Spain.

Ed, we are having robot weld fusion and porosity issues with some of our pulsed MIG stainless 3/8 fillet welds. Are there best weld practices we could use to resolve the weld issues”?

It’s questions like this that get resolved with these resources.

There are numerous weld issues that occur daily in robot cells, however I am sure that after the 3000 hours that it’s taken me to develop this program, I believe that I have provided soulutions for 99% of the common robot cell weld problems.

Robot and Manual MIG Welding Process Control
Item [3a]

The Self Teaching MIG Book.

“Manual – Robot MIG Weld Process Control Simplification”.

Written by E Craig. (170 pages).

This is a “self teaching” Manual and Robot MIG Weld Process Control, Training book. This book is an essential tool for MIG weld quality / productivity optimization. With this book you will learn Ed’s unique, weld process control “Clock Method” which provides a simple, highly effective, easy to remember approach to the selection of optimum MIG parameters for any manual – robot carbon steels, alloy steels and stainless applications. Answer the 160 questions and you are ready to present the robot process control training program.

It’s questions like this that get resolved with these resources. “Many of our robot welded parts have both weld fusion and weld distortion concerns. If we turn up the weld heat to improve the fusion, we add to the distortion. We need either parameter or best practice solution to resolve the problems”?

Item [3b]

The DVD Video.

“Manual MIG Process Controls Made Simple”.

Produced by E Craig. (Runs 60 minutes).

When training, a good video is always worth a million words. This DVD is a great visual tool in the presentation of the simplification of the selection of optimum, CV MIG parameters, for all those manual steel and stainless applications.

This unique MIG training DVD has been purchased by hundreds of companies in 14 different countries. Companies such as GM, Caterpillar, Case, Ford, Volvo, Tower Automotive, Magna, Dana, ABB, Babcock, Boeing, Delphi, TRW, Monroe, Johnson Controls, Textron, Genesis, General Dynamics, General Electric and numerous others.

Ed took over 2000 hours to develop this unique, Robot Process Control Training Program.

Questions?., Call Ed. 828 337 2695. E-Mail ecraig@weldreality.com.

To order click here.

Item 4 Description of The Management – Engineers MIG book:
Note with this order you get to choose an above training program.

To Order Click Here.

MIG Welding Management“A Management & Engineers Guide To MIG – Flux Cored,
Weld Quality – Productivity and Costs”

Perhaps you wish to change that too common “play around” with the weld control approach to MIG and flux cored welds. Or maybe you are fed up with hearing, “why change the way we have always done it”. Maybe you want to get away from being influenced by weld equipment, consumable sales reps. Possibly you wish you had a better understanding of the MIG and Flux Cored weld costs. Or you want to know how to optimize the MIG and Flux Cored weld production and quality. The bottom line is you are likely an individual that likely believes in the importance of taking ownership of the weld process, equipment and consumables that have a key role in both your career and companies’s profits.

This book was written by E Craig, With 600 pages. It’s the most comprehensive book ever written on the weld management – engineer requirements necessary to consistently attain the highest MIG – Flux Cored weld quality – productivity at the lowest possible weld costs.

Note. This book and the Process Control training program, reveal the importance of Process Control expertise and implementing Best Weld Practices. There are many weld cost benefits attained from weld personnel that can fully control and optimize the performance of the weld Process and consumables utilized on any applications. Please do not confuse weld experience / weld skills with weld process control expertise. If you think your weld personnel have the weld expertise necessary to optimize the common MIG or Flux Cored welds, ask the best welders in your facility the following simple weld question.

Hello Craig.

I’m reading your Weld Management – Engineers Guide book, and by the way  it’s the best Welding Reference book that I have ever bought! Since the book was written a few years ago, what in 2016 is your best choice for welding wires for GMAW and FCAW carbon and stainless steels?

Thanks. SO. Quebec. Canada..

Answer: Steve ref my weld consumables and weld equipment recommendations, nothing has changed in 2016 from the recommendations I provided in my books and materials, except of course today we have more unnecessary BS consumable weld claims and more weld equip with costly useless Bells and Whistles.

Question: You want to make a carbon steel MIG fillet weld on a 1/8, (3.2mm) to a 1/4, (6.4mm) plate. You have a common 0.035 or 0.045 (1 – 1.2mm) MIG wire with an argon 15 – 20% CO2 mix. An experienced weld decision maker would be aware that a good weld mode start point for this weld would be to set the wire feed and voltage at the start point of spray transfer. What is the MIG spray transfer start voltage and wire feed rate, (inch/min or m/min), that is required for the world’s most common, 0.035 – 0.045 (0.9 – 1.2mm) MIG wires. If you ask five weld personnel in the weld shop the above fundament MIG question, you will likely get five very different answers, and most of the answers will be incorrect.

E-mail.2007: Ref the Weld Management Book:
Hello Ed. I recently purchased your “Management and Engineers Guide to MIG Welding”. The book and CD training program was everything I had hoped they would be and then some! Thanks Ed for having the motivation and courage for your web site and the information you provide. I have not yet come across an opinion that I did not share or a concept I did not admire. ”The more I learn from you, the more I find there is to learn.” Cutting through the BS and producing the best possible welds at the lowest costs, is what makes learning your Clock Weld Method exciting. Your weld process knowledge combined with your personal opinions (which I find, hit the nail on the head every time) has made these resources one of the best weld shop, and training tools I have seen to date. Worth much more than you charge.
Thanks a million Ed. Regards. Fraser Rock.

E-Mail.
Ed. I received your “A Management & Engineers Guide to MIG” and the training CD. Thanks a million Ed. I am pleased to learn about MIG and Flux Cored welding. I am 33 years old from north-east Italy. I work as a mechanical designer in a company that designs and manufactures rolling mills all around the world. All the welded structures built are heavy parts made in carbon steel plates, welded almost always by multi pass manual MIG welding. The engineers and project managers in our technical office spend a lot of money and time buying expensive weld calculation software and complying to the confusing ISO-EN standards, then we have the advice of the so called weld consultants and weld associations. The bottom line is most of us have had absolutely no idea about how the MIG process works or how to recognize a good or bad weld procedure. With your book I finally have found a logical solution to understanding and controlling the MIG process.
Regards. Oscar Cavezzan Italy.

Another benefit of weld process control education.

WELD COSTS – WELD QUOTES – WELD COSTS – WELD QUOTES – WELD COSTS – WELD..

Understanding and quickly working out weld costs, is an important management, engineering and supervision function. All my programs simplify this subject.

Real MIG – Flux Cored weld costs is a subject that’s rarely discussed in most weld shops, however in the front office, there is typically frequent discussion about the costs of the MIG weld gases and the weld wires. While weld consumables typically are no more than 20% of the cost of MIG or FCA welds, there is usually minimal conversation on the real costs of the common welds produced in the weld shop.

If the prime weld decision makers in a weld shop, are not aware of the real costs of their common MIG or Flux Cored fillet welds, how can that weld shop control it’s weld costs, or how can that company optimize it’s profits?

In the front office of any weld shop, there should never be a mystery with the costs of the common welds that are daily produced in the weld department.

The most common, global MIG or Flux Cored steels and alloy steel welds, are 5/16 – 1/4 – 3/16, (8 – 6 – 5 mm) fillet welds,. In the hundreds of weld shops that I provided weld optimization for over a 5 decade period, if I was to ask the key weld decision makers in the shop, who were aware of the weld costs per-foot or per-meter, of their common 1/4 (6.4 mm) steel MIG or Flux Cored fillet welds? I am sad to say, that I never met one individual who could quickly provide the correct answer.

I believe that many in the weld industry would agree with me that it’s rare to find a weld manager, supervisor or technician that can provide a simple cost calculation for their common daily welds. The unique, MIG – Flux Cored weld process controls and best practice weld resources that are provided below, simplify working out the costs of any MIG or Flux Cored weld. The bottom line, any weld decision maker should have the ability with a glance at the wire feeder, to be able to within a couple of minutes, to work out the shop’s real costs of that MIG or Flux Cored weld.

When the majority of global weld shops focuses on the welder’s skills, rather than on the weld process control expertise, you know something is not quite right.

For decades, while the majority of the global MIG – Flux Cored welders “played around” with their weld controls, the majority of weld industry managers and supervisors placed their focus on their welder’s skills and their length of weld experience. The sad reality is minimal focus was placed on the weld Process Controls – Best Practice expertise available with the personnel in the weld shop and just as important with the personnel in the front office.

For decades,
THIS LONE VOICE IN THE WELD INDUSTRY WILDERNESS, HAS BEEN STATING;

“That without MIG – Flux Cored weld process control expertise, and the implementation of Best Weld Practices, it’s impossible for any weld shop to consistently attain optimum MIG – Flux Cored weld quality and productivity, always at the lowest possible weld costs”

Too many managers in large companies, love to waste money on pulsed
MIG weld equipment and it’s useless electronic bells & whistles.

Many global companies pay a huge price for weld management process ignorance,
it’s ironic in 2014, that in Asia, where weld labor costs are typically miniscule, that you will find the majority of large weld – fabrication companies are demanding very expensive Chinese made pulsed MIG equipment. The sophisticated electronic, Pulsed MIG equipment typically costs $6,000 to $15,000. It’s a weld reality that In 2014, as it’s been for at least 25 years, most of the weld shop managers who make the Pulsed MIG equipment purchase decisions, are rarely aware that the sophisticated, pulsed equipment, will in contrast to a $3,000 to $4000, well made, regular CV, MIG power source, will result in the following:

Please note that with most MIG fillet welds, that weld fusion is typically marginal, and the prime purpose of any weld is to provide consistent, optimum weld fusion..

[a] The costly, pulsed MIG units will on most welded parts > 2.5 mm, produce welds with less weld fusion and welds with more porosity than spray welds made with the much lower cost CV MIG equipment. The reason for the pulsed MIG weld fusion and porosity concerns is a simple one. The pulsed MIG welds spends 50% of their arc on time, with a pulsed back ground weld current of less than 100 amps.

In contrast to the traditional, open arc, spray weld from a low cost Constant Voltage MIG unit, It’s logical that any pulsed weld will put in less weld energy. For those that want proof, it takes five minutes. First make sure your weld personnel are trained to set optimum MIG spray settings with a CV MIG power source. (if they can’t answer the MIG weld questions at the top of the page, they are not trained). Have the welders produce a single pass, 1/4, 6 mm, horizontal, spray fillet weld. Section both welds in the middle, and examine the weld fusion and porosity in both the Pulsed & the Spray weld cross sections.

[b] A key characteristic of a Pulsed MIG weld, is with the “lower open arc weld energy potential” than a conventional MIG spray weld,the pulsed mode will benefit specific, limited, manual, heat sensitive applications such as weld cladding (require low weld dilution) and thin heat sensitive, < 3 mm aluminum welds. Pulsed MIG benefits are also attained with automatedall position, pipe welds, in which the MIG wire stick out, the weld travel speeds, and the weld weaves are controlled. The weld shop reality however is that 99% of all manual MIG welds, will with low cost argon 2 - 20% CO2 mixes, achieve the highest possible weld quality, (with minimal spatter) at the lowest possible weld costs. However the MIG spray welds, will rarely be attained by weld personnel that play around with their weld controls. To optimize MIG - FCA weld quality - productivity has never required sophisticated MIG equipment or three part gas mixes, theses welds simply need to be made by individuals who have received training in MIG - FCA weld process controls and best weld practices. Most weld sales and MIG equipment reps, either don't know, or they don't want their customers to know, that the highest MIG weld quality and productivity, can be made by the lowest cost MIG equipment and two part gas mixes. That costly weld application qualification typically means little with the pulsed MIG process. By the way, I hope you have considered the fact that each new pulsed MIG unit bought into the plant should typically require a new, costly, weld re-qualification of your existing weld procedures. (not a concern with CV equipment and spray - short circuit welds) The reason for the re-qualification, every new model of pulsed MIG equipment will typically will have major electronic changes, and for a given wire feed rate the pulsed output changes could dramatically impact the weld variables and weld energy produced. The bottom line is this. If for example your company spent thousands of dollars on a pulsed MIG weld application qualification 5 yrs ago, and then purchased new pulsed MIG equipment today, your company would from possibly a weld code requirement or from a knowledgable weld engineer's perspective need to re-qualify the welds and create new procedures. Not re-qualifying the pulsed weld with the new pulsed equipment, is just another one of those weld shop concerns that one day will have dramatic weld cost liability consequences for some companies. [c] That new, overpriced pulsed MIG weld equipment will in many instances rarely get through it's short warranty period without circuit board issues that will likely impact your companies weld quality - productivity. When the pulsed unit does require repairs, expect to pay thousands of dollars, and pray it wont take more than a month or two to repair. Please also be aware that your organization added to the pulsed equipment longevity and durability concerns when the pulsed equipment purchased was made in China. With Chinese pulsed MIG units I believe you should expect extensive costly repair and weld performance and weld quality issues. In contrast, that low cost, regular, USA made MIG equipment should typically be in weld shop service, without requiring repairs, for 10 to 25 years. Also note most electricians should have the ability to repair regular CV equipment at low costs. I have evaluated global pulsed MIG equipment for approx three decades. There are THOUSANDS of words I've written on pulsed MIG weld - equipment issues in the pulsed MIG, and MIG Equipment Evaluation sections at this site. Also I have written over 100 pages in, "My Management - Engineers Guide To MIG" book, on what's wrong with the Pulsed MIG process, and of course the subject is covered well in my manual -Process Control training programs, which by the way also tell those that have purchased pulsed MIG units, how to get the best weld quality - productivity out of that pulsed equipment. It's a sad reality, that in the weld industry, that the most widely utilized MIG process has for decades been surrounded by confusion, and that the only companies that usually benefit from the more costly pulsed MIG equipment sales, are the companies that make and sell the pulsed MIG units. The reason managers and engineers around the globe, buy into the pulsed hype is the too common weld shop reliance on salesmanship for MIG weld equipment advice, and also of course, the general weld process control - best practices ignorance. So those of you making MIG equipment budget decisions, instead of wasting thousands of dollar in the purchase of pulsed MIG units, I would recommend the weld shop purchase of a well made USA Miller - Lincoln. CV $3,000 - $4,000, 350 - 450 CV MIG power source, (Miller Delta Welds lead the way). If selecting European, CV MIG equipment, consider ESAB, CV units. To get the best out of this lower cost equipment, you will need then to spend a whopping $400 on my MIG or Flux Cored Weld Process Controls - Best Weld Practices resources. If the person who is in charge of welding can read a power point program, they are qualified to do the training with these unique, easy to teach resources. Management needs to be aware of the important relationship between Weld Process Control Expertise - Best Weld Practices, with the attainment of consistent, optimum weld quality - productivity, at the lowest possible weld costs The weld industry is unusual in that it's a high tech industry in which the majority of weld personnel have for decades played around with the two primary weld controls. In these circumstances, an industry has been created in which too many weld decision makers rely on sales advice and lack in-depth weld process control - best practice expertise. Instead of watching a manual welder or robot programmer "play around" with their MIG or flux cored weld controls, consider the benefits of trained weld personnel who are provided with MIG weld process and best practice expertise. Those manual welders, will always provide optimum weld settings that produce the best possible weld quality, always with the highest weld deposition rates. And those trained robot programmers could instantly set the data on any dumb, blind robot that's attached to a low cost, CV, MIG power source, and consistently produce the highest possible robot weld quality and productivity. When you purchase the following MIG and Flux Cored weld process control resources, you are purchasing programs that I developed over five decades. These easy to learn and easy to teach training resources are updated frequently.. When the major robot companies and MIG power source manufacturers failed to optimize the robot weld quality - productivity with some of their important customers, the following are a just a few of the robot weld applications in which I was asked to resolve weld quality - productivity issues: FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES - HARLEY BIKE FRAMES - INDIAN BIKE WELDS - NEW VW BEETLES & MERCEDES CAR SEATS -WORLD'S LARGEST CATERPILLAR TRUCKS - I WAS THE FIRST PERSON IN THE WORLD TO SET ROBOT WELDS ON DIFFICULT, POWER PLANT, BOILER TUBES TO HEADER WELDS - ALSO THE FIRST TO SET ROBOT CLAD WELDS INSIDE BOILER WATER WALLS - FIRST TO SET ROBOT WELDS ON A 40 inch PIPE - FIRST TO SET ROBOT WELDS ON AN OIL RIG - FIRST TO SET MULTI-ROBOTS IN A WELD CELL WELDING LARGE ALUMINUM APPLICATIONS.

One good thing with MIG or Flux Cored weld issues. If someone in the company has weld Process Control expertise, they should have the ability to provide instant weld resolutions, and create dramatic weld cost reductions. Then with the implementation of best weld practices, they can ensure the weld issues do not occur again:

If you have worked in a weld shop that uses MIG – FCAW, you may have watched weld personnel “play around” with the MIG power source controls, which have hardly changed since the 1950s. In the play around weld shops, consistent optimum weld quality is rare, as is attaining the highest weld productivity with welds at the lowest costs.

If you have worked in a weld shop, you may have often seen, those unqualified, weld sales reps, providing weld advice to the weld shop supervisors and managers.

You may have been in the weld industry for decades. I would like you to think back and see if you can recall any weld decision maker that could look glance over at a the MIG wire feed control, and the weld arc, and then in less than three minutes tell you the real costs of the weld being produced. I believe that most weld shops, the management weld shop cost focus has usually been on the costs of the MIG – FCAW consumables which typically account for less than 18% of the total weld costs.

If you have worked in a weld shop, you must have wondered why the lack of MIG weld equipment uniformity. Why is the shop always trying different weld equipment, wires and gas mixes? Why are there more than two MIG gas mixes in the cylinder rack? (Any plant that uses more than two gas mixes for traditional steel and alloy steels applications, sends a message that they are not in control of the weld shop). Why also are there so many weld consumable sizes and types? and does the weld shop really need those costly Metal Cored and Flux Cored weld wires?

Managers should consider, how cost effective is it to put welds on the parts then grind the welds off?

If you worked in a weld shop, you must have wondered how much money was spent each year on the purchase of unnecessary grinding wheels and wire brushes, and how much weld shop labor costs were wasted daily on unnecessary grinding, unnecessary weld cleaning and unnecessary weld rework.

If you worked in a weld shop, you must have met weld Quality – Inspection personnel that waste hours discussing weld defects, and you may have thought it unfortunate that these guys lacked the weld process knowledge and ability to prevent the weld defects from occurring

These weld process controls – best practice programs, will provide anyone with important weld information that is not available at any global university or college that provides either weld engineering or welder training programs.

When anyone in this industry gives themselves the ability to instantly create dramatic, weld quality improvements and weld cost savings, their weld career prospects should be unlimited, especially when working in an industry in which MIG – Flux Cored weld process controls and best weld practices will for years be rare.

PLEASE NOTE: I established www.weldreality.com in 1997, this was before Google was a company. In the 1990s web site building technology was crude, and my web site expertise, and control of the English language was, and still is laughable. This site may not be a sophisticated looking, however it’s a site full of practical, real world weld information based on the 50 years I’ve spent in this business.

2017.. Please note in an industry guided by salesmanship, I have accepted advertisements, for which I paid a steep price in my search engine optimization. The bottom line is this. I am aware that at this site where there are well over millions of words, that you will find many typo errors, and the web format style will look forever look dated, however I don’t really care. I simply write the way I think and speak, and I always try to avoid BS. I m proud of the fact, that for the last 20 years, this site has been the world’s largest and most practical MIG – Flux Cored – TIG web site on Best Weld Practices – Weld Process Controls. You may get tired of reading this stuff, however, I will never get tired writing it. Thank you for reading. Regards Ed Craig

If the weld industry employed personnel with MIG weld process control expertise, and all the costly pulsed MIG equipment, three part gas mixes, and metal cored wires were pulled from the global weld shops, the bottom line would be that there would be no negative impact on the weld quality and productivity. It typically takes me or the people I have trained about 30 minutes to prove this point. This is something I have proven in hundreds of weld shops in thirteen countries.

As few sales reps have ever managed a weld shop, why would any weld professional want weld advice from a sales rep?The 1970s, was the time when weld managers, engineers, supervisors and technicians should have stopped listening to the mostly unqualified, too often biased weld sales advice that inundates the global weld industry. Fifty years later, in the majority of global weld shops you will still find the same sales influence, the same process confusion and the same daily weld BS. This industry, will I believe, get the respect it deserves, when the key weld decision makers cut the umbilical cords attached between themselves, and the companies that make and sell weld equipment and consumables.

Weld Quality – and Weld Costs Benefits are readily attained when weld shop management, engineers and supervisors actually take ownership and responsibility for the weld processes – and weld equipment that daily creates the profits for their organizations.

The Manual MIG, Flux cored, Robot MIG and Advanced GTAW Training Programs are available with the Management book,

MIG – Flux Cored – GTAW weld process control – best weld practice expertise, open the doors to increased company profits, & also improves weld career prospects.

WELD PROCESS CONTROL – BEST PRACTICE TRAINING AT YOUR FACILITY?

Their are two ways to get my manual – robot MIG and flux cored and TIP TIG weld Process Control – Best Weld Practice Training or Self Teaching Programs.

[1] You can order one of my programs,

[2] You can request my customized training program at my place in Asheville NC, or at your facility.

One Popular Seminar I provide for large companies.

” HOW TO MANAGE A WELD SHOP & ENSURE MAXIMUM DAILY MANUAL – ROBOT
WELD QUALITY AND PRODUCTION, ALWAYS AT THE LOWEST WELD COSTS”.

MY CUSTOMIZED TRAINING PROGRAM FOR YOUR WELD SHOPS.:

The following customized MIG & flux cored, Weld Process Control & Best Weld Practicetraining program is suited for managers, engineers, supervisors, technicians, QA personnel and welder trainers.

In the competitive global weld – fab industry, increased profits will be achieved by those companies that employ weld decision makers that do not have to rely on weld sales advice, and have the Weld Process Controls and Best Weld Practice capability for weld process optimization in their organization.

PROCESS TRAINING & WELD COST REDUCTION OPPORTUNITIES FOR YOUR COMPANY:

Extensive weld cost savings will be found in any weld department in which manual weld personnel and robot technicians no longer have to play around with their MIG and flux cored weld controls.

Extensive weld cost savings are generated in weld departments when weld processes, weld consumables, weld transfer modes, weld deposition potential and weld costs are understood by the weld decision makers.

Extensive weld cost savings will be generated when the manual / robot weld quality is consistently optimized, weld rejects and rework are reduced, and the prevention of weld defects is understood.

Extensive MIG weld equipment and consumables cost reductions are enabled in weld departments in which the weld decision makers no longer rely on weld sales reps for weld advice. These cost benefits will be many;

[] The weld decision maker will have the reasons and proof that your company does not need to purchase costly pulsed MIG equipment that’s typically loaded with useless electronic bells and whistles.

[] The weld decision maker will no longer need to purchase three part gas mixes or a variety of different gas mixes.

[] The weld decision maker will not require the costly metal cored wires and will think twice about the flux cored wires purchased.

[] The weld decision maker will dramatically reduce weld fumes and weld grinding enabling a cleaner safer environment and also reduce the requirements for grinding wheels & discs.

A QUALIFIED MANAGER WOULD BE AWARE THAT IT DOES NOT NEED A WELD TEAM TO RESOLVE ANY MANUAL – ROBOTS WELD ISSUES, IT SIMPLY REQUIRES ONE QUALIFIED INDIVIDUAL WHO CAN THEN TRAIN THOSE THAT ARE INVOLVED WITH WELD DECISIONS.

My customized programs typically last one to two days and i will also instantly resolve any weld issues you have in the plants and provide optimum procedures. Any participants will in a few hours become manual or robot MIG – FCA weld process controls experts.

For more info. E Craig. 828 337 2695. E-Mail ecraig@weldreality.com.

THE VALUE OF MIG WELD PROCESS CONTROL – BEST PRACTICE
TRAINING IN THE AUTO – TRUCK INDUSTRY:

E-Mail. Ed I wanted to send update about that E-Town, DANA plant
that you visited a few years ago. As you know on your first visit, our robot MIG welding lines were producing less than 40 Ford F-150 truck frames per-hour, and over 90% of the frames required extensive weld rework.

Thanks to your Robot Weld Process Controls – Best Practices Training program, and your process and consumable recommendations, the robot weld results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures, and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks! Ryan Good.
A grateful engineer, and a grateful DANA Corporation.

Note The DANA corporation is a tier one supplier and a world leader in the supply of drive line products such as frames, axles, drive shafts, and transmissions for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.

WELD PROCESS CONTROL TRAINING FOR ANY WELD SHOP USING MIG – FCAW.

E-Mail. Dear Ed, I want to let you know that by using your MIG – Flux Cored weld process control – best practice methods in our plants, we have now dramatically improved our weld quality – productivity and reduced our labor – filler metal costs by approx. 45%. We intend to utilize your training program in all our plants.
Lawrence Bower CWI/CWE.
Chief Welding Engineer.
NCI Group. Houston TX.


Mangers, please be aware that Universities, Colleges & Training Facilities, don’t provide the weld industry with the weld process control – best weld practice resources that are provided here. If you feel you are on top of your processes try the following weld quiz.

Ed’s MIG Weld Process Controls & Best Practice Quiz.

Ed’s Flux Cored Weld Process Control & Best Weld Practice Test.

Home Page weldreality.

To order click here.


FOR THOSE LOOKING TO HIRE MIG – FLUX CORED WELDERS, PLEASE NOTE THE SO CALLED “SHORTAGE OF SKILLED FLUX CORED, TIG AND MIG WELDERS” HAS FOR AT LEAST A DECADE SIMPLY BEEN WELD FICTION..

Many global managers believe there is a so called shortage of skilled MIG, TIG and Flux Cored welders. The reality is this. Once any company provides the unique best practices – process control training programs at this site, with less than FORTY HOURS of hands on training, irrespective of the weld skills or lack of weld experience, all the personnel taking the training will have the ability to instantly set optimum weld parameters and to attain without “playing around”, uniform, consistent, optimum MIG – TIG or Flux Cored welds on any application, and that includes all code quality welds.

Questions call Ed. 828 337 2695.

E Mail ecraig@weldreality.com