Welcome to Em’s Weld Process Controls – Best Welding Practices Programs.
If you are involved with welding decisions, the following are the most comprehensive and practical MIG – Flux Cored – TIG & TIP TIG self teaching & training programs,

 Heard in most weld shops. Why change, this is the way we have always done it and can you give me some time to play around with the weld controls.

During the 1990’s in my position as the Corporate Weld Mgr. for ABB Robot Div, North America, I provided my unique robot weld training programs which I had been developing during the previous decades. The robot program was the first global Robot MIG Weld Best Practices and Process Controls, Self Teaching – Training program.

Unfortunately in the 1990’s, the senior management, engineers and supervisors at most global auto – truck companies were not aware of what this subject was, and that their employees required it for robot weld quality – productivity optimization. Thirty years later in 2018, little has changed. However these programs since that time have evolved yearly, and are the most effective robot weld  process controls – best weld practice programs that could be presented to any persons responsible for the robot MIG welds.

Weld Reality Home Page Info.
  • In the auto – truck industry, you will find maintenance electricians, millwrights and plumbers each shift making unqualified weld changes to robot welds. It seems someone forget to tell the management in these plants that most of these individuals know nothing about robot MIG weld process controls – best practices.
  • A look at the root cause reasons for global manual and robot MIG and flux cored weld process confusion.
  • Manual or robot weld costs, who in the front office has a clue?
  • Lets take a look at the the global influence of SALES ADVICE on manual – robot weld quality, productivity & costs.
  • Why lasers don’t belong in the auto – truck industry, and management and those robot & laser aluminum welds.
  • In large industries you will find that billions of dollars are lost each years due to lack of weld process controls and best weld practice expertise.
  • Why the auto – truck company management waste millions of dollars annually on the unnecessary purchase of laser weld – cutting & tracking systems.
  • There is no reason for a global skilled MIG – Flux Cored welder shortage.
  • The corporate managers / engineers at Chrysler did not have loose millions of dollars each year on a simple robot welded part.
  • Ford, reasons for it’s robot steel frames and aluminum weld issues.
  • The auto management and engineering influence on the billions of dollars lost every year in vehicle recalls & law suites.
  • Why it’s difficult to  trust a Chinese company to create products or construction projects that require optimum weld quality.
  • Few of the global robots daily achieve their production – quality potential.

Weldreality Home Page 2

  • Dow Chemical engineers and management were stuck in a 1960’s weld time warp.
  • Magna techs, lots of attitude, but still lack Robot MIG Weld Process Control expertise.
  • What do ship yards and auto plants have in common?
  • Why the common global QA weld inspection practices often fail.
  • When the Chrysler welds fail,  their  solution. Ship the parts to Mexico.
  • Nothing more ridiculous than pathetic FEMA involved with USA weld specs.
  • Would Einstein have this a similar theory on MIG welding?
  • Self Shielded flux cored wires, their effect on North Ridge Earth Quake failed welds.
  • With Motoman there were always numerous robot / weld weld issues.
  • More reasons managers and supervisors  raise the white flag.
  • For four decades, three part MIG gas mixes have simply been a CON job.

Weldreality Home Page 3

  • The Volvo plant mg. was wrong in wanting to hire skilled welders to run his robots.
  • Lawyers may want to read how poor MIG – Resistance welds affect vehicle crashes.
  • At this Volvo truck plant, their was no manager or engineer weld ownership.
  • The fear of weld process change is natural without process expertise.
  • In contrast to other industries, the engineer to workers ratio is very high in the auto – truck industry. Yet nest weld practices & process controls are typically none existent.
  • Many plant or manufacturing managers do not report their real robot weld quality and productivity costs to their corporate peers.
  • Numerous weld quality and productivity issues are generated when designers of welded parts would not know a good MIG or resistance weld if it was four inches from their nose.
  • Why Americans and their sad infrastructure, should give consideration the the welds before they drive across that next steel bridge.
  • This large auto – truck wheel nfg. produced poor quality welds and their inexperienced management helped drive this company out of business.
  • Is it logical to want those that are paid to daily make mfg. process decisions to understand the scope, accountability and responsibility of their profession.
  • Why GM senior management wasted nearly a million dollars to weld the Corvette.

It’s a sad reflection on the global weld industry, that for decades,the majority of companies that utilize MIG robots will not be aware that the robots they own will have rarely reached their weld quality or weld production potential.

Weldreality Home Page 4.

  • Their were many weld issues in the plant, and the management were blaming the wrong people.
  • The most costly pulsed MIG Lincoln power source versus the least costly CV Lincoln MIG power source.
  • it was the Miller Maxtron & Invision that helped put this global wheel mfg. into Chapter 11.
  • After introducing their latest  pulsed equipment, most weld equipment mfgs. continuously made changes to deal with the equipment issues without notifying their customers about the issues and the negative impacts caused to welds.
  • Japan always made the worst MIG welding equipment, and the Japanese auto – truck weld specifications often belong in Disney Land.
  • Why purchase a costly pulsed MIG power source for gage metals, when in most instances the lower cost, more durable CV MIG power source is superior.
  • Why purchase a costly pulsed MIG power source for welding steels > 0.080,

OPTIMIZE ROBOT MIG WELDS

Poor manual and robot weld manufacturing practices are the norm  throughout the global automotive and truck industry.

The majority of the robot and manual MIG welds, and also resistance welds are rarely optimized in most auto – truck plants. In the 1990 ‘s I started an auto -truck industry BAD WELD Section. Note, after a decade I had to stop with this is section as the bad part weld  recalls reported on the web were endless. In 2018 little  has changed. One thing that should frustrate any engineer. manager, supervisor or technician, is why over three decades does this important industry seem to lack the ability to control a process which has two simple weld controls?

How to manage and optimize robot MIG weld quality & productivity.

Whats in Part One?

  • This section can be the catalyst you require to implement robot weld improvements.
    Remember  most robot weld issues start in the front office.
  • Liability consequences from the common lack of weld process controls in robot cells.
  • Robot weld issues and consequences that occur when the world’s worst weld process is used.
  • Is your company subjecting  employees to unnecessary Carcinogenic fumes and dust?
  • I could have saved Chrysler over 50 million dollars, but Chrysler management ignored my weld advice and the advice from US Steel.
  • Robots and galvanized – galvanealed weld quality.
  • The management check list for when considering the purchase of a robot.
  • Why would any management bring a high tech laser into their plant while the employees involved with the MIG process were “playing around with the two simple controls on the sixty year old weld process.
  • American Axle, Lincoln Power Wave and robot weld cracks on Ford Axles.
  • It pays to understand weld issues that occur with costly pulsed MIG equipment.
  • The daily necessary costs many companies derive by taking advice from a sales rep.
  • AG. Simpson management and engineers did not want to get involved with their GM bumper robot MIG weld issues.
  • Freight Liner wanted robot weld quality – productivity improvements on robot MIG welded parts that have a million mile warranty.
  • After 2 years, Fanuc, Lincoln &  AGA could not shed light on these robot lamp post weld problems.
  • What should your robot weld production quality and productivity goals be?
  • Why most auto plants don’t attain the expertise required for process optimization.
  • The global costs associated with the common poor utilization of Robots in MIG cells.
  • If the management & supervision does not fully understand MIG – Flux Cored weld costs, how can it control the costs and optimize the profits from the weld dept?
  • Why are there few qualified global weld managers, engineers and supervisors?
  • Is your weld shop manager or supervisor fed up with the endless useless weekly weld team meetings that rarely resolve the weld issues.
  • Why VAW and Ford should have sued ABB – ESAB and the integrator over the poor weld performance of the ESAB Robot Arcitec power source.
  • Why not evaluate your MIG – Flux Cored process control – best practice expertise.
  • Why in the last 5 decades, most global Weld Educators have failed the weld industry.
  • There are companies like Panasonic that make robots and MIG weld equipment, and yet the designers of their equipment obviously  lacked MIG weld process control and best weld practice expertise.
  • Why the auto industry manual & robot MIG training programs typically fail.
    Poor manual & robot weld manufacturing practices are the norm  throughout the global automotive and truck industry.

    The majority of the robot and manual MIG & resistance welds are rarely optimized in most auto – truck plants. In the 1990’s I started an auto -truck industry BAD WELD Section. Note, after a decade I had to stop with this is section as the bad part weld  recalls reported on the web were endless. In 2018 little  has changed. One thing that should frustrate any engineer. manager, supervisor or technician, is why over three decades does this important industry seem to lack the ability to control a process which has two simple weld controls?

How to manage & optimize robot weld quality & productivity. Part Two.

  • With welding robots, black belts, yoke poke and joke and a university education are useless attributes without robot weld process controls – best weld practice expertise.
  • Lawyers may want to read how poor weld quality & vehicle collisions offers great financial opportunities.
  • Weld team meetings are only required when the key weld decision makers lack process control expertise.
  • When management recognizes that process expertise is lacking, weld issues quickly dissipate.
  • The fear of weld process change is natural on weld shop floors, especially when weld decision makers are not in control of the processes they own.
  • Why many plant or mfg. managers will not report their real robot weld quality and productivity costs to their corporate peers.
  • With robot cells, there should never be a need to add manual welders to compensate for the robot weld issues.
  • It’s unfortunate that before they purchase, USA drivers will rarely see the welds on the underside of their vehicle.
  • As a future managers or supervisors you may be interested to read how easy it is to save millions of dollars each year with large scale weld fabrication & mfg. applications.
  • Managing robot cells or ship yards, process expertise gets the results. Take a look at how in less than 3 months, Ed (now Em) saved the Aker Kaverner, (Philadelphia Navy Yard) ship yard, millions of dollars annually through rapid flux cored – MIG weld quality – productivity improvements.
  • The weld disease called Globular MIG Transfer, and those guys in the front office were not even aware they had it.
  • What is the real weld production potential from any MIG welding robot.?
  • Why ISO has failed robot weld mfg.

MIG Weld Advice for that lonely, frustrated Robot Technician.

  • Robot technicians. These poor lonely guys need all the support they can get, however there are many resolutions to their daily robot weld problems.


Robot and Weld Optimization. This is the Self Teaching and Training Process Control – Best Practice Resource that gets the results.

Bad welds, bad welds, what’s the management gonna do?

Optimum Flux Cored Welds without playing with weld controls:

When building oil tankers in the USA, these flux cored welds were acceptable from the ship yard management.

A welder who was supposed to be qualified made this weld with a so called weld procedure.


Flux Cored or MIG. It’s easy to save millions annually in large weld shops.

Examine how weld / fab quality – costs are out of often out of control in ship yards and with other large projects.


Flux Cored 
or MIG. Pipe Welds problems and resolutions.

Flux Cored or MIG. Common Weld Defects – Weld Problems & Weld Resolutions.


SELF SHIELDED Flux Cored Wires and the many weld Issues they generate.

SELF SHIELDED (SS) Flux Cored Wires influence on the 13 Billion dollar Northridge Earthquake

Learn why you don’t use the ridiculous SS wires when you want quality welds.


Test your Gas Shielded Fllux Cored weld process knowledge with Ed’s Weld Quiz.

Flux Cored Weld Issues / Resolutions in SHIP YARDS.

Welders often shy away from weld automation as they are rarely taught the required weld process control requirements.

Establishing manual or automated welds, the weld shop personnel should
be able to provide answers to simple weld questions like this?

Lets see, this is a common, automated carriage weld making a 1/4 (6 mm), MIG Spray fillet weld. The MIG wire is 0.045 (1.2mm) and the gas mix is the common argon 80% – 20% CO2.

  • I set the MIG WF at ____.
  • The MIG weld volts will be____.
  • The carriage weld travel rate is ____.
  • The best torch angle is____ degrees.
  • The best torch push angle is ____ degrees.
  • Woops getting spatter, I better _____the volts.
  • Woops, getting undercut, I better____ the_____.
  • The weld is oversize, so I can increase the weld speed without touching the WF, so now I have to _____the weld volts.

The next weld I have to set on that automated weld carriage is with a 1/16 (1.6 mm) E70T-1 flux cored wire with a CO2 gas welding the same 1/4 fillet weld. Could you then provide the flux cored wire data

  • Set the flux cored wire feed ____ inch/min.
  • The FCA weld volts will be____.
  • The carriage weld travel rate is ____.
  • The best torch angle is____ degrees.
  • The best torch push angle is ____ degrees.
  • Woops getting spatter, I better _____the volts.
  • Woops, getting undercut, I better____ the_____.
  • The weld is a little oversize so I can increase this weld speed without touching the wire feed, so now I have to _____the weld volts.

This or any weld data would be no big deal, if you learnt my Weld Clock process control method which makes it easy for me to remember weld data for any MIG – Flux Cored consumables or weld. Remember, if you have to ask about MIG or Flux Cored weld data, or you play around with weld controls, can you call yourself a “weld professional”.

Ed’s MIG & Flux Cored, Self Teaching – Training, Weld Process Control – Best Practice Resources.

TIG and TIP TIG

Regular AC/DC TIG with Advanced Electronic Controls.
Many weld personnel don’t comprehend the new electronic features available on traditional AC/DC  TIG equipment, and many weld decision makes need to be aware of why they should no longer be considering the traditional TIG process.

By the way my TIG self teaching – training program available in the training resource section simplifies and provides the best possible training  methods that anyone would require to attain the best possible results with modern TIG equip.

If  you or your company is using regular GTAW for your manual welds, or Hot – Cold Wire TIG  for your automated welds, you are likely wasting your money and labor resources, and also reducing your weld & part quality potential..

TiP TiG. The world’s best manual – automated TIG  process for most all position code quality steels and alloy welds. 

For those interested in attaining the highest weld quality at the lowest costs, for the majority of alloy weld applications the regular TIG process should more than a decade ago have been replaced by the TiP TiG process. Apart fron the TIG data Ed provides an advanced TIG and TIP TIG training program. These programs  simplify the two processes and provide  the most comprehensive data ever written, and also reveal the unique differences between TIP TIG, regular TIG and Hot Wire TIG,

Ed introduced TIP TIG  to both North America and Australia in 2009..

Oxy Fuel Cutting, Gas & data:

Info on Acetylene, Propane, Nat Gas, Propylene & Mapp Gases.

If you don’t apply process controls and best practices to your oxy – fuel cutting applications, you have missed an opportunity to maximize the profits you could have attained

Oxy Fuels. Information and Cutting Data.