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Welding Books

MIG Welding Book, Management
A Management & Engineers Guide to MIG Weld Quality, Productivity and Costs

Gas Metal Arc Welding Book
Manual and Robotic (MIG) Gas Metal Arc Welding Book

MIG and Flux Core Welding Book
Flux Cored and MIG weld process controls

Manual MIG Welding Book
Manual MIG Welding Process Control

(Also in Spanish)
" Proceso de Soldadur MIG Manual "

Welding CD's

Robot Welding CD
Robot MIG welding. Best Weld Practices and Process Controls

MIG Welding CD
Manual MIG Welding. Best Weld Practices and Process Controls

Flux Core Welding CD
Flux Cored Best Weld Practices and Process Controls

MIG Welding Process Controls
DVD Film "MIG Process Controls Made Simple"

Order these MIG Welding or Flux Cored Training Materials Now

ED CRAIG. www.weldreality.com.

The world's largest website on MIG - Flux Cored - TIG Welding

MIG Welding CD

Advanced TIP TIG Welding
TIP TIG Welding is always better quality than TIG and 100 to 500% faster with superior quality than TIG - MIG - FCAW.






If you want to control those robots or
establish uniform weld practices and
process controls in your weld shop,
this is the resource you need.


"MIG & Pulsed MIG. Training CD:

Best Weld Practices and Weld Process Controls
for Robots and Manual Welds"

Price $275. Order here.

MAGNA is an auto parts supplier that has over two hundred plants and generates over 15 billion dollars annually.

Dana does close to 7 billion dollars annually in auto / truck part sales.

Both these companies in 2004 and 2005 had specific facilities or personnel that decided to establish a Robot Weld Best Practices and a Robot Weld Process Control training program for their key technicians, engineers and management robot personnel.

After reviewing the available North American training resources both Magna and Dana companies purchased Ed's unique training program.

Consider this an ever evolving book or training resource for your company.

A few of the >300 Power Point slides are provided on the world's
most effective robot MIG weld best practices
and MIG weld process controls.


So mary variables influenece robot welding issues.

Inconsistent arc starts. Poor start stop / data,
birds nest, balls on end of the wire, crater issues,
weld inconsistency. Why not get to the root cause of
the robot weld problems that cause robot down time.

There are many reasons for that robot weld spatter.
Using globular parameters, wire stick out vaiations,
incorrect voltage and lack of parameter knowlege.

Inconsistent welds from poor placement of leads?
You can play around with the leads or know the best
location for the volt sensing leads.

A complete evaluation of MIG equipment is provided. The reasons
are given why on the majority of steel applications
you can attain the same weld quality from a $2000 power
source as you can from a $12000 power source.

Just one of the real world differences
between pulsed and spray.

A salesman can say one thing about welding equipment and
consumables, Ed's training programs will show the weld reality.




E-Mail July 2006

Ed I wanted to send update about that E-Town plant that you visited a few years ago: As you know on your first visit to this plant, our robot lines were producing less than 40 Ford truck frames per-hour and the majority required extensive weld rework. Thanks to your weld process and consumable recommendations, your training books and your MIG manual / robot Weld Process Control Training Program, today the results from our employees are staggering. Yesterday this plant hit very close to a record of 76 truck 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 truck frame line.

Many thanks!

A Grateful Employee of
Dana Corporation.



Robot cell equipment decisons? Make the right choices
as they will effect, the robot quality, productivity and down time.

Restarts. TCP controls. Robot collision options.
Weld joint tracking options?

When you make the right choices befor you purchase the robots,
you have a sound investment in your robot equipment.

Optimum weld procedures, the best weld equipment and the most
expensive robot equipment, will mean nothing without calibration knowlege.

An in-depth evaluation of short circuit transfer and the
correct robot weld parameters for all steel and
stainless gage applications.

After this training session no weld decision maker in your
organization will ever have to
play around with those MIG parameters.

A simple weld process control method shows your employees
how to instantly set optimum Spray Transfer parameters
and why on many steel applications, spray is preferred to pulsed.


With this robot MIG weld process control training, the following four production, robot weld goals are simple.

[1] Attain no more than two percent daily weld rework from each robot.

Attain maximum weld speeds and weld deposition rates per-application.

Achieve less than 20 minutes each shift for robot down time.

[4] Have a weld team that completely understands the tools and equipment they are asked to operate and manage.

The weld reality is that fewer than 10% of the companies that have purchased robots will in 2007 attain these goals.



Everything you need to know about pulsed, its benefits, its
disadvantages and how to set those many pulsed parameters.

Every weld decision maker should know how to
best utilize pulsed, short circuit and spray.




Dear Ed Craig,

I am a welder living and working in Australia. I found your website 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 just weld and if it looks good that's enough, but this is not good enough for me. I want to know my settings are right and do quickly and simply, thats why I am using your weld resources.

Yours sincerely
I C Ormrod.


There are many things designers can do to
improve robot weld quality and productivity.


April 2005. Dear Mr. Craig ,

Mr. Craig. Your web site was recommended by a friend, I really enjoyed going through it ! you must be congratulated for making a rather dry subject like welding both colorful and interesting'.

Wishing you all success and happiness,
With warm regards T.A.Ramesh

Grafs Welding Institute and Consultancy Services ,
Mumbai, India.

As most weld equipment provides no weld data, Ed provides
a unique simple approach to setting the weld equipment.

Once you learn the the clock method, setting any weld consumable on
MIG equipment for any application becomes simple.

With any MIG or flux core wire there are only four
settings for every possible application. Do you
or your employees know those 4 setings?

While Ed shows you the four simple settings for every
sheet metal weld application in the world, some weld
equipment manufactures will try to sell you their
electronic MIG equipment offers 4 million wave forms.

Setting correct arc lengths. Using wire stick outs
to resolve robot weld issues Poor arc starts. Wire
burn backs. Crater fill. End Data. Every weld
decision maker needs to know the little things that
can impact weld production or quality.

Why weaves benefit certain applications and we
need to limit them on others.


If you want robot rework of less than 3% and maximum, daily weld productivity
I would recommend you implement these 7 logical steps to Robot MIG Process Controls.


E-Mail to Ed.

Having read your site from cover to cover I loved every bit of it as it provides the only "non-biased" view of the MIG welding process and related equipment and consumables. Keep up the great work,

Regards Bill.

Devon, England.

E-Mail: Hi Ed.

Its Matt Finn, I spoke with you on the phone a couple of weeks ago. Well contrary to the beliefs of my coworkers I must say your concepts on GMAW are worth trying. Your story of reading weld literature and finding it was not as it seems inspired me to do the same. Over the last three years all I have done and continue to do is read from a variety of welding resources. So this past week I have focused my study on the "hands-on" practical aspect. Its amazing what you learn from having your nose in the arc rather than observing from out side a fence. From this approach I now fully understand how and why globular transfer is not a reliable mode of transfer, especially when utilizing it for high travel speeds (50- 70imp). Tonight thanks to your books I was able to figure out how you achieved robot speeds of 70 to 100ipm in spray mode. I went snooping around the plant and found an old style of diffuser that was shorter than our common ones. I then took your advice from your WELD MANAGEMENT AND ENGINEERS book and cut about a quart inch off the end of a tip. With having the tip recessed in to nozzle allowed for a longer stick out dropping the amperage but still within the spray range. The longer wire stick out permitted me to run higher WFS (deposition rate) without the extra amperage that would cause unwanted weld defects. The spatter was minimal and easy to remove. Also the recessed tip and diffuser were spotless. After thinking about it I now makes sense.
Thanks for your contribution to my weld education.
Matt Finn. USA.


Ed, I purchased your robot process control training materials a few months ago for my employees and we have revised all our robot tube welding parameters with great success. The welds quality and production on our automotive exhaust pipes & mufflers has been greatly improved.
Thanks and best regards, Dodge Juhan

Robots & "Weld Cost Expertise"

If you are a manager or engineer and concerned about the "Robot Weld Cost Controls" in your organization don't you think you should have the ability to answer these two simple Weld Cost Questions?

Your company is welding a small, high strength, auto part. The steel part is
3 mm thick and the welds are made with a robot.

The weld gas used is argon - 10% CO2 and the weld wire is the common 0.045 (1.2 mm) E70S-6 wire. The weld transfer mode used is spray transfer. The weld parameters.

Wire wire feed 400 ipm,
280 amps,
26 volts.

The robot welded part has 10 - 3/16 (4.8 mm) fillet welds. The welds are 2 inch (5 cm) in length. The 3/16 fillet is the world's most common size fillet weld made on auto / truck parts

Question 1: Approx. how long do you think it will take the robot to weld one part. Should take no more than 5 minutes for this answer.

Question 2: How much MIG weld metal used per-part. (No more than 10 minutes to answer this).

Question 3: With the following data, what is the weld cost of this part?

Labor $40 /hr.
Gas costs $1 / hr.
Wire costs $1 pound.

If it takes you more than 20 minutes to answer these three straight forward weld process questions, you are not in control of your weld costs. To simplify weld costs, use this training program. I would also recommend one of my books titled,

"Management Engineers Guide to MIG. Click.




No one wants weld decision makers playing around with weld controls. No one wants endless team meetings that never seem to resolve those robot or manual weld issues,

Everyone who gives a dam about his job and future should want the opportunity to provide consistent, optimum weld quality and productivity. The capability is there provide the necessary process training for your weld personnel: Price $275.
Order here.



A sample of a few of Ed's weld application experiences:

  • Hayes Lemmerz. Large wheel manufacturer. Provide the plant with MULTI-MILLION cost reduction solutions for it's automated (MAXTRON) aluminum and steel weld issues.

  • VAW. Eliminate extensive ABB robot, aluminum pulsed weld issues. Optimize weld productivity on aluminum Ford SUV car seats.

  • Ford Motor. Requested to solve numerous robot weld issues at Fords largest Frame Plant.

  • Genie. Increased robot productivity and established robot process training programs construction (boom) equipment.

  • AG Simpson. Canada. GM / Chrysler bumper parts, robot weld quality, training and productivity solutions. Resolved GM issues.

  • ABB Transformer Div. Improved robot transformer weld productivity
    on transformers.

  • Chrysler. Ask to resolve Neon, robot cross member self shielded flux cored weld problems that resulted in more than 12 million dollars in weld rework.

  • Case. Improved the new 98-tractor cab robot welds.

  • TRAK / Textron. Reorganize train and automate weld shop.

  • Combustion Engineering. Established unique robot MIG nickel weld procedures for overlay robot welds inside boilers.

  • New York Power Authority. Provide advice on robot welding stainless containers for spent fuel storage.

  • Combustion Engineering. Established unique “MIG robot weld procedures” for boiler tube to header welds.

  • F&P America. Major Honda parts supplier. Provided weld process training for their robot operators.

  • Harley Davidson. Provide new robot weld procedures, for improved weld productivity on bike frames.

  • Mascotech Michigan. Established robot weld process control programs for 300/400 series stainless, robot welds, 98 Ford Mustang manifolds, Chrysler Jeep and Hummer manifolds.

  • Johnson Controls Mexico. Solved robot weld issues and increased productivity by 20% on new 98 VW Beetle car seats.

  • GM Bowling Green KY. Established MIG weld procedures for new robot welds, 98 Corvette frame.¨

  • Volvo. WV. Set new robot weld data and training for 98 Volvo Trucks.

  • Monroe. Consulted to establish uniform global weld best practices and robot process controls for 5 plants.

  • Citrogen Spain. Established robot weld process controls and training for car seats

  • TRW provided robot improvements on steering parts.

  • Club Car. Set robot weld data for worlds first robot line welding aluminum golf carts.

  • Imperial Oil/ Esso, Canada Trained SMAW welders to use FCAW for pipeline welding, produced over a million dollars in annual cost reductions.¨

  • Mascotec KY. Provide new plasma welding procedures to increase productivity on automated tube weld lines.

  • Textron Trained Thailand Army on MIG and FCAW weld repairs on Textron 270k tensile armored tanks.

  • General Electric. Provided GE Diesel Div facilities, with weld process and weld cost analysis.

  • Caterpillar. Established robot weld procedures for the worlds largest trucks.

  • Provided weld cost analysis and MIG / flux cored training for two Ship yards.

  • Harley Set the robots to weld their new heavy duty frames.

  • Two new patents developed in 2007. [1] Anew improved method of Pulsed MIG cladding water wall boilers. [2] A new MIG method for attaching insulation on boilers