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 robot techs, maintenance personnel each shift making unqualified weld changes to robot welds. Someone needs  to tell their management that most of these individuals know little about robot MIG weld process controls – best weld practices.
  • A look at the root cause for global manual and robot MIG,  flux cored  and TIP TIG weld process confusion.
  • Manual or robot WELD COSTS,  who in the front office has a clue?
  • The global negative influence of SALES ADVICE on manual – robot weld quality, productivity & costs.
  • Why lasers and aluminum have a hard time in the global auto industry.
  • From Navy ship yards to auto plants, billions of dollars lost each years due to lack of management ownership and weld process expertise.
  • There is N0 reason for a global skilled MIG – Flux Cored welder shortage.
  • Chrysler management looses  hundreds of  millions of dollars annually on  simple robot welded parts.
  • Ford, reasons for it’s robot steel frames and aluminum weld issues.
  • Why it’s difficult to  trust a Chinese company to create steel products or construction projects that require optimum weld quality.
  • Few global welding robots achieve their production – quality potential.
 Weldreality Home Page 2
  • Dow Chemical engineers stuck in a 1960’s weld time warp.
  • Magna techs, lots of attitude, lacking in  Robot 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, they ship the parts to Mexico.
  • Nothing more ridiculous than FEMA involved with USA weld specs.
  • Would Einstein have this a similar theory on MIG welding?
  • Self Shielded flux cored wires effect on North Ridge Earth Quake welds.
  • Motoman and Panasonic numerous robot / weld weld issues.
  • Welding, why the managers and supervisors raise the white flag.

.Weldreality Home Page 3

  • Volvo management wrong in wanting to hire skilled welders to run robots.
  • Lawyers may want to read how poor welds affect vehicle crashes.
  • No manager process ownership at  Volvo truck plant.
  • The fear of weld process change is natural without process expertise.
  • The engineer to workers ratio is high in the auto – truck industry, yet best 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.
  • Most designers of welded parts would not know a good MIG or resistance weld if it was four inches from their nose.
  • Why Americans should give consideration to the welds before they drive across that next steel bridge.
  • This large auto – truck wheel mfg. produced poor quality welds and their inexperienced management helped drive this company out of business.
  • Should managers have process ownership?
  • GM  management, weld process ignorance and 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 as usual the weld management were blaming the wrong people.
  • How this costly Lincoln pulsed MIG Lincoln power source compares with 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 purchasing a costly pulsed MIG power source for gauge metals, when usually a lower cost, more durable CV MIG power source is superior.
  • Welding steels? Why purchase a costly pulsed MIG power source?,


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?

For robot managers and technicians, how to optimize robot MIG weld quality & productivity

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

The consequences of management and engineers who fail to understand the importance of weld process control expertise and the implementation of the best weld practices that are necessary to optimize weld quality, minimize weld costs and reduce weld liability consequences.

A look at  global industries & the lack of ability to control weld quality.

Auto – Truck with  focus on Ford Motor company mfg and weld issues,

Auto – Truck industry. Take a look at poor mfg. practices, weld issues and recalls at Chrysler – GM – Buick – VW – Honda – Nissan – Mitsubishi – Mini – Land Rover- Hyundai and others in the Auto – Truck Industry.

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. PIPE Welds Problems and Resolutions.

Flux Cored & poor weld management in Ship Yards & other Large Weld Shopsse.

Examine how the weld and fabrication quality – costs are out of often out of control in ship yards and on most  other large projects.

Self Shielded Flux Cored Wires and the many weld Issues they generate.

Self Shielded Flux Cored Wires influence on the 13 Billion dollar earthquake.

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.


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.