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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


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.


"Best Robot MIG Weld Practices and Weld Process Controls
for gage to any thickness parts "

Ed's robot process control package which is item 2, was developed for all carbon steels, low alloy steels, stainless,nickel steels and aluminum robot applications welding 20 gage to any thickness. The following is a brief description.

The Training CD: "Robot MIG Weld Best Practices
and Process Controls"

[2b] The Book: "Manual and Robot MIG Welding Process Controls"

[2c] The DVD film:
"Manual MIG Process Control Made Simple"

Total Cost for items 2a/b/c $395 plus shipping.

Order this Welding Training Program

[Item 2a] The Training Power Point CD:

MIG Welding Training"Robot MIG Weld Best Practices & Process Controls.

Irrespective of the robot application, this program provides every
possible optimum robot MIG weld requirement for Short Circuit,
Globular, Spray and Pulsed welds.


At one time, Ed was the Weld Manager for the North American ABB Robotics Division. He was the first person in North America to establish Robot Weld Process Control Training. During his 40 plus years as a weld process control expert, Ed has assisted hundreds of companies in 13 countries in attaining robot MIG, TIG and flux cored weld quality and productivity optimization. In the last two decades, Ed has resolved numerous Motorman, Fanuc, OTC, Cloos, Panasonic and ABB robot weld quality and productivity issues.

Robot Weld Quality - Productivity - Rework parts < 4 mm.

When robot welding thin gage applications avoiding weld burn, attaining consistent weld fusion a
nd minimizing distortion are important to decreasing weld rework. For thin gage welds, you can utilize 4 common weld transfer modes, short circuit, globular, low spray data or pulsed. The issue many weld decision makers have, is which is the optimum weld transfer mode and which are the optimum parameters and weld consumables for those carbon steels and stainless gage welds. Instantly select the correct robot weld data for any thin application. The easy to remember data was developed by Ed to attain optimum weld quality with the highest possible robot weld productivity.

Robot Weld Quality - Productivity -
on parts > 4 mm

Robot spray transfer and pulsed transfer welds on parts > 4 mm to any thickness requires unique weld fusion and weld
deposition considerations.
Ed established the robot weld data for the world's largest trucks manufactured by Caterpillar and set optimum robot data for the world's biggest selling truck frames the Ford F150. Ed has set robot welds on ships, boiler walls, trains, pipe lines, oil rigs, farm / construction equipment etc. and established optimum robot welds with most major auto and truck part suppliers in twelve countries.


The robot weld production - cost data that's presented in this program is extremely beneficial as few robots achieve their true daily weld production potential. Being aware of the factors that influence your robot down time and weld production efficiency potential and providing instant solutions to the many daily robot weld problems, will have a dramatic impact on your weld quality and production costs.
Once you present this program, typically you can anticipate a 20 to 50% increase in your daily robot weld productivity.

Process Control training provides the ability to provide resolutions to weld issues. With a few hours exposure to this animated CD program, your employees will have the ability to provide instant solutions to things like:

[] Robots and Lack of Weld Fusion.
[] Robots and LAvoiding Weld Burn Through.
[] Robots and Weld Start Issues.
[] Robots and Optimizing Weld Tie Ins.
[] Robots and Avoiding Wire Burn backs.
[] Robots and Minimizing Contact Tip Issues.

[] Robots and Weld Crater Issues.
[] Robots and Weld Arc Start Instability.
[] Robots and Inconsistent Welds.
[] Robots and Poor Weld Profiles.
[] Robots and Weld Spatter.

[] Robots and Weld Porosity.
[] Robots and Weld Undercut.
[] Robots and The unique requirements for attaining high deposition and high speed welds.
[] Robots and The unique requirements for multi-pass welds.
[] Robots and Solutions to Variable Gaps.
[] Robots and Process solutions to Part Dimension Inconsistency.

educe liability concerns. Minimize weld rework. Optimize weld productivity:
Many companies will purchase two robots to produce weld production that could be attained from one robot. Most companies are not aware of the real weld deposition rates per application and the robot speeds that could be attained and few companies will establish the process controls necessary to ensure consistent daily weld productivity with minimal robot down time. This training provides your employees with the process knowledge and the confidence they need to daily attain maximum weld productivity without robot down time.


When all your weld decision makers know how to fine tune and set optimum robot MIG weld data, the weld quality / productivity results will be both immediate and dramatic.

No more weld trials to find optimum weld data, equipment or consumables. No more time wasting playing around with weld controls. Imagine the benefits of having employees with the ability to instantly apply optimum process data that will ensure minimum downtime, minimum rejects and minimum weld rework. When those robot weld problems occur, you can call a team meeting or watch your trained workers instantly react with the correct weld process resolutions to the weld issues.

Bring all your weld decision makers to a training room. Place this CD in
a laptop. Project the program to the screen. In eight hours everyone has the necessary robot MIG data to establish Best Weld Practices and implement Weld Process Controls. The results are immediate.

[] No more personnel playing around with the robot MIG weld controls.

[] No more exasperating meetings discussing weld issues that never seem to get resolved.

[] A dramatic reduction in robot down time.

[] Less concerns for product liability weld issues.

[] Be aware of the real world part and weld gap tolerances for all robot MIG welds.

[] When you have personnel using unique weld data and techniques that are focussed on attaining consistent weld fusion and minimum weld quality issues, the results are minimum weld rejects and weld rework.

[] With every weld you will ensure maximum weld deposition rates and the fastest possible robot weld speeds.

[] Reduce the influence of sales and vendor advice and provide logical justification for MIG equipment and consumables.[] Your weld personnel will have the resources to establish highly cost effective, uniform Best Weld Practice for any plant and provide highly effective Weld Process Controls for each robot cell.

Think of the benefits of working in a manufacturing weld shop environment in which best practices without sales bias and optimum robot weld process controls are established. Your product liability concerns are reduced, and all the weld decision makers take a uniform, professional, practical approach to the daily attainment of optimum, robot weld quality and productivity.

Note: As this CD program simplifies process controls, and presents the answers to the majority of questions that could be asked, the person presenting the program needs no weld process control expertise.

Robot & Manual MIG Welding Book[Item 2b] The Training Book.

"Manual / Robot MIG Welding Process Controls"

Written by Ed Craig.
(170 pages).

For more Information, click here.

This is a self teaching manual and Robot MIG Weld Process Control Training book. This book presents Ed's unique, process control Clock Method which provides a simple, highly effective approach to the selection of optimum MIG parameters for any robot carbon steels, alloy steels and stainless applications. This book is an essential tool for MIG weld quality / productivity optimization and a great resource for those participating in this training program.

MIG Welding Video[Item 2c] The Training DVD film.

"Manual MIG Process Controls Made Simple".

Produced by Ed Craig. (Runs 60 minutes).

Remember "a picture is worth a 1000 words. This DVD is a great visual tool in the presentation of the simplification of optimum, CV MIG parameter selection using Ed's Weld Clock Method.

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 3000 hours to develop
this unique, Robot Process Control Training Program.

Item 2a-b-c. Total cost $395 .

To order item 2
Click here

From Ryan at Dana Corporation USA:

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 truck Ford F-150 frames per-hour and the majority required extensive weld rework. Thanks to your robot weld process control / best weld practices training program the results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames jobs 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 F-150 line.

Many thanks Ryan Good. Dana Corporation.

2007: Update from Ryan. Hey Ed:
Just thought I would drop you a line and let you know that in the beginning of April we will be working on switching over the 5th Dana plant to ther process recommendations of an 0.040 wire and the traditional spray mode, instead of the 0.052 (1.4mm) wire and using the Rapid Arc (Lincoln's pulse program). Thanks again RG.


E-mail From: Tom Plummer. Tenneco USA:

Good afternoon Ed.

Tenneco has plants all over the world. We have been very enlightened by your " Robot MIG Weld Process Control" training materials " We are slowly implementing your process control and best practice concepts to the shop floors.

E-mail. From Jose Ignacio Moreno. Johnson Controlls. Spain.

Ed. I work as manufacturing engineer in Johnson Controls Alagon (Spain). We mainly build car seat structures. And we have some robot welding cells. Last week I received your robot process control material, which I've been reviewing. I find it really interesting and practical.Your approach to weld process control is unique and it certainly works. It seems you have been in our company, as most of the robot MIG weld issues you address are part of our every day work. Thank you JM.

E-mail From Marcus di Sabella
Magnaflow. CA.

Ed, I just received your robot process control materials and within five minutes of skimming I found many flaws in our weld techniques and process data. These materials will be very helpful to our organization! Thanks for your expertise and prompt service!

Process Engineer.
Car Sound Exhaust System, Inc / Magnaflow Performance Exhaust.
Rancho Santa Margarita, CA.


Ed y
our 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. Tonight thanks to your books and training resources I was able to figure out how you achieved robot speeds of 70 to 100 inch/min in the spray mode. As per your instructions I found a gas diffuser that was shorter than our common ones. I then took your advice from your WELD MANAGEMENT AND ENGINEERS book and cut about a 6 mm 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 like weld burn through. The spatter was minimal and easy to remove. Also the recessed tip and diffuser were spotless. A

Ed Thanks for your contribution to my weld education.
Matt Finn. USA.

This program is applicable to all types
of robots and weld equipment.


The Weld Issue. The macro of the weld on the right indicates lack of MIG weld fusion when robot welding thin gage 1.5 to 2.5 mm carbon steel parts.

The robot weld data used was a typical short circuit setting. The 0.035 (1mm) wire feed was set at 280 inch/min, (7 m/min). 170 amps. 18 volts. The weld travel rate was 20 inch/min, (0.5m/min).
The weld gas was argon - 15% CO2.

As an experienced weld decision maker you know you can improve the weld fusion by changing the 0.035 wire weld parameters to the following....

[a] Set the highest attainable short circuit weld settings.

Provide Wire Feed____ Amps____ Voltage ____ Travel Rate____

[b] Set a higher energy controlled globular transfer weld settings.

Provide Wire Feed____Amps____Voltage ____ Travel Rate____

Set the start point of spray transfer parameters and change the gun angle.

Provide Wire Feed____Amps____Voltage ____ Travel Rate____

[d] Change the weld wire to 0.045 (1.2mm) and set suitable pulsed parameters that
will not burn through.

Provide Wire Feed____ Amps____Voltage ____ Travel Rate____

The above required weld settings tell you the importance of process data awareness. This resource will give you and your organization, the ability to make "playing around" with weld data an obsolete function in your organization.

Don't play around with your robot weld controls and settings,

provide instant solutions and avoid weld defects.

Ed set the robot welds for Volvo Cabs, Corvette, Harley and Ford 150 truck frames.

[] Robots and Weld Rework: It's typical in many plants to find excess weld rework required for those robot welds. This program identifies the root causes of weld rework and deals with all the major issues that impact weld quality and rework.

[] Robots and Weld Defect Prevention. All the common weld defects are covered and the robot process control data is provided to ensure your defects are minimized and weld rework in minimum.

[] Robots Weld Deposition Rates and High Speed Welds: This training shows you how to always attain the maximum weld deposition rates and provides the data necessary to attain the highest possible
robot weld speeds.

[] Robots and Down Time. High robot speeds and production efficiency become meaningless when the robot spends 30 minutes to 120 minutes minutes per-shift in down time. For every issue that causes down time there is a resolution presented in this program

[] Robots and MIG Equipment: The training cuts through the sales bias of weld equipment and makes you aware of why Inverters and Pulsed MIG equipment can enhance weld quality on some applications and may have dramatic negative weld quality impact on other applications.

[] Robots and Weld Process Calibration: Few global robots have received correct robot / power source calibration. In attaining consistent daily weld quality and production performance the contractual requirements of calibration are provided and need to be understood by engineers and managers.

Ed set this robot to weld a 40 diam pipe.

1980s to early nineties:

[1] Ed was the first person in North America to set a robot to weld all position flux cored weld for a 40 inch pipe line.

[2] Ed was also the first in the world to set ASME qualified robot pulsed MIG welds for the difficult task of welding boiler pipe to headers. Customer was ABB Combustion Eng.

Ed was the first person in the world to set on site, robot Inconel / stainless pulsed MIG clad welds inside a water wall boiler.

[4] Ed was the first person in the USA to set a "multi robot line. 4 robots" to successfully MIG weld a large aluminum part. (golf car frame)

In the early nineteen nineties, Ed established
the multi-robot pulsed MIG data, for these aluminum golf cart frames.

For the best in robot weld quality consider TIP TIG.

Note: As Ed has a reputation for weld process control simplification.
The weld decision maker who presents this presentation needs
no robot weld process control expertise.


Visit Ed's MIG Welding and Flux Cored Training Materials.