Welding Books

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

Manual and Robotic (MIG) Gas Metal Arc Welding Book

Flux Cored and MIG weld process controls

Manual MIG Welding Process Control

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

Welding CD's

Robot MIG welding. Best Weld Practices and Process Controls

Manual MIG Welding. Best Weld Practices and Process Controls

Flux Cored Best Weld Practices and 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 - TIG - Flux Cored Welding MIG & Flux Cored Training Resources.	2 to 10 times faster than TIP TIG Welding for superior weld quality than Pulsed MIG and Flux Cored Welding

MIG Weld and Flux Cored.
Weld Best Practices and Process
Control Training Resources:

Optimum Manual and Robot Best Weld Practices and
Weld Process Controls, cannot be implemented
without Weld Process Control Expertise.

Ed's Process Control and MIG Welding Books, Manuals and CDs.

If you are teaching your self, or providing weld process control training for others, the following resources are essential in attaining MIG and flux cored weld process optimization for any applications...

Item.1. The Book: "A Management & Engineers Guide
To MIG Weld Quality, Productivity and Costs"

Item 2. The Robot Weld Process Control Training Resource: There is no where in the industrial world, that you will find a better Robot MIG Training or self teaching resource. "Optimum Robot MIG Welds from Weld Process Controls".

Item 3. Manual MIG Process Control Training Resource. The ultimate Manual MIG training or self teaching resource.
" Manual MIG Weld Process Optimization from Weld Process Controls".

Item. 4. The world's most comprehensive flux cored training or self teaching resource. "Optimum Manual and Automated Flux Cored Plate and Pipe Welds.

Item 5a."Proceso de Soldadura MIG Manual"
(MIG Made Simple. Self teaching in Spanish)
Item 6a. The Self Teaching MIG Book/ Video.
(MIG Made Simple in English).

Scroll down for more details and ordering info...

You will note there are no advertisements at this site. Ed is determined to keep sales bias out of his weld process advice and training programs. The following MIG and flux cored weld process control training resources are the keys to establish Best Weld Practices and to implement cost effective Weld Process Controls. These valuable training resources have been developed for both manual and robot weld personnel.

Item.1. The Book:

"A Management & Engineers Guide
To MIG Weld Quality, Productivity and Costs"
The most comprehensive book ever written on the total process requirements necessary to establish MIG Weld Best Practices and Weld Process Controls.

Written by Ed Craig. (Over 600 pages). Cost $195.

For more information on this book, click.

A MANAGER, ENGINEER, SUPERVISOR OR TECHNICIAN DOES NOT REQUIRE THE ABILITY TO WELD, HOWEVER THESE INDIVIDUALS SHOULD KNOW HOW TO MANAGE AND OPTIMIZE THE PROCESSES CRITICAL TO THEIR COMPANY.
MIG and flux cored weld results achieved with the world's most utilized welding equipment are frequently influenced by inaccurate and biased weld sales advice. This book cuts through the sales induced weld process myths and is the world's most comprehensive, practical book on optimizing and managing steel and stainless, MIG / flux cored manual and robot applications.
Note. If you are interested in achieving manual and robot MIG and flux cored weld process optimization for the weld personnel in your organization, scroll down and ensure you take a look at Ed's very unique, MIG and flux cored, Best Practices and Process Control Training Resources. Scroll down.

To order item 1. Click here.

E-mail.
2007: Hello Ed;

I recently purchased "A Management and Engineers Guide to MIG Welding". The book is everything I had hoped it would be and then some! Thank-you for having the motivation and courage to make this kind of information available. I have not yet come across an opinion that I did not share or a concept I did not admire. ”The more I learn, the more I find there is to learn.” That is what makes it all so exciting. Weld process knowledge combined with your personal opinion (which I find hits the nail on the head more often than not) has made this book one of the best teaching and training tools I have seen to date. Worth every penny. Fraser Rock. Weld Engineer. .Hydroform Solutions. Ontario. Canada.

"Some times you don't pick the book, the book will pick you" said Rubin Carter. How many times have you read a 300 page technical book and found that only one or two pages in the book are relevant to your career. With Ed's weld process control resources you will find every page is relevant to optimizing MIG and flux cored weld quality and productivity.

Item 2. This unique robot, self teaching and training package comprises of 3 items. This MIG robot weld process control program was developed for all welds on carbon steels, stainless, nickel and aluminum applications, welding 20 gage to any thickness.
"Optimum Robot MIG Welds from Weld Process Controls".

[2a] The Training CD: "Robot MIG Weld Quality & Productivity Optimization, from Robot
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.

[2a] The Robot Training CD:

"Robot MIG Weld Quality & Productivity Optimization from the implementation of
Robot MIG Weld Best Practices and Weld Process Controls.

Developed by Ed Craig.
Updated each year.

This is the most comprehensive, practical robot MIG process control training program ever developed. In global auto / truck plants, the average robot MIG "real world" weld production efficiency is 60 - 70%, the average "real world" robot down time per shift is 45 minutes, the average robot weld rework is 10 to 40% and the majority of the MIG welds that pass visual inspection would on internal evaluation, reveal lack of weld fusion. Irrespective of the carbon steels, low alloy steels, stainless or aluminum robot applications, this CD training or self teaching program deals with all the primary root causes that impact robot down time, robot weld quality and productivity.

This unique program delivers highly effective robot MIG weld data and solutions for all your
Short Circuit, Globular, Spray and Pulsed MIG applications.

IF YOU ARE TEACHING YOUR SELF, OR PROVIDING TRAINING FOR THE ROBOT WELD TEAM, THIS UNIQUE, ANIMATED CD POWER POINT TRAINING PROGRAM REQUIRES EIGHT HOURS TO PRESENT. NO WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THE PROGRAM. SIMPLY POP IT IN A LAP TOP AND CLICK.

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 and one of his first customers was General Motors. During his 40 plus years as a weld process control expert, Ed has assisted hundreds of companies in 12 countries to attain optimum robot MIG, TIG, Plasma and flux cored weld quality and productivity. In the last two decades , Ed has resolved numerous Motorman, Fanuc, OTC, Cloos, Panasonic and ABB robot weld quality and productivity issues.

ATTAINING OPTIMUM ROBOT MIG WELD QUALITY AND PRODUCTIVITY ON "THIN PARTS". When robot welding carbon steels, stainless or aluminum thin gage applications, avoiding weld burn through and attaining consistent weld fusion are common issues. This one of a kind weld process control training program provides the resolutions to all the primary root causes of unacceptable weld quality, weld rework and robot down time.
From a product liability perspective, it's ironic that a good percentage of so called visually acceptable robot MIG welds on gage parts, would with an internal weld evaluation reveal extensive lack of weld fusion. There is no need for concern once Ed's 7 steps to robot weld process controls are implemented.

When establishing new robot weld data, or looking for a weld solution for a problem robot weld, it's beneficial when the robot weld decision maker has the ability to instantly select the correct weld transfer mode and provide optimum weld data and optimum robot weld techniques. For robot welding thin gage welds < 3 mm, you can utilize six common weld transfer modes, RMD, CMT, short circuit, globular, low spray, or pulsed. With this program, you will not have weld personnel "playing around" with the weld data as this program provides optimum weld data for all your applications. As this weld data is supplied by North America's leading robot weld process controls expert, you will note a dramatic reduction in your robot down time and will see immediate improvements in the weld quality and productivity.

OPTIMUM ROBOT MIG WELD QUALITY AND PRODUCTIVITY ON "THICK PARTS". Robot spray and pulsed welds on parts > 2 mm to any thickness, require unique weld fusion and high weld deposition considerations. A few hours with this CD program and your robot weld personnel will have the ability to;

[a] deliver consistent, acceptable weld fusion and weld quality,
[b] provide weld settings that ensure the highest possible weld deposition rates delivering
maximum robot weld productivity with all welds,
[c] eliminate robot down time,
[d] dramatically reduce your robot rework,
[e] provide instant resolutions to all the primary variables that daily impact the robot weld quality or production.
[f] reduce your product liability concerns,

ROBOTS AND MIG WELD DEFECT PREVENTION: Included in this program, is the most comprehensive program ever developed on manual and robot "MIG Weld Defect Prevention". There is no other robot training program available that shows the root cause of the majority of robot weld defects and provides instant, logical robot resolutions.

OPTIMIZE YOUR ROBOT WELD PRODUCTIVITY: Few global companies attain maximum weld production efficiency potential from their robot cells. Many companies will purchase two robots to produce weld production that could be attained from one robot. Few companies correctly address the root cause that daily influences robot down time. Most companies are not aware of the real weld deposition rates and the maximum robot speeds that could be attained and few companies have established process controls that will ensure consistent daily weld productivity. This training CD will provide your employees with the process knowledge and confidence they need to daily attain maximum weld productivity with minimum robot down time.
A FUNDAMENTAL POINT ABOUT PROCESS MIG WELD EXPERTISE & WELD OPTIMIZATION. So you have invested >$200,000 on those two robots and the fixtures and you have hired a person with ten years MIG weld experience to run the robot cell. Many managers quickly learn that MIG weld experience often does not equate to weld process control expertise.

Is there a value to weld process control knowledge? this is is a question I should not have to ask, yet its a question many mangers should ask.The following MIG weld process control question should show you the value of weld process expertise. If you asked your most experienced robot personnel these two fundamental process questions and they they don't know the answers or they take more than 5 minutes to answer, ask your self this. Why have we invested $200.000 in robot equipment and processes without providing the necessary robot weld process control training for our employees?
Question.1.: With your robots, you are MIG spray welding with an 0.035 (1 mm) wire feed set at 600 inch/min, (15.2m/min), 28 volts welding a common 3/16 ( 4.8 mm) fillet weld at a robot weld travel rate of 35 inch/min (89 cm/min) and you are having wire feed issues. The robot technician intends to use spray with an 0.045, (1.2 mm) wire. What 0.045 wire feed setting and voltage will he have to establish to maintain the same production with minimum robot speeds of 35 inch/min?

Question.2.: You are using 0.035 (1 mm) MIG wire and short circuit to robot weld 2 mm, carbon steel parts. The 0.035 robot weld data is, wire feed 350 inch/min (8.9m/min) and- 20 volts. You decide that the short circuit process is not providing enough weld fusion so you ask the robot tech to switch over to an 0.045 (1.2mm) wire in the pulsed mode. Could the technician, without playing around with the parameters, instantly provide the optimum pulsed wire feed / amps, voltage and travel rate, settings that will not burn through the 2 mm parts.
If your robot weld personnel cannot answer fundamental MIG weld process control questions without looking in a book, does that mean they will take unnecessary time to do what many robot weld technicians will do, "play around" with the weld data, till hopefully they get close to where they need to be? With this CD program, give your employees eight hours in the classroom and watch them take control of the robot welds on your shop floor.

Note: Ed is one of the leading global MIG weld process control experts on high speed, high deposition rate welds. He established the robot weld data for the world's largest trucks manufactured by Caterpillar and set optimum robot data for Volvo truck cabs. He set the robot welds on the Corvette body, Harley bike frames and the Ford F150 truck frames. Ed developed a patent for MIG high deposition welding gage parts and in ten different countries. Ed has optimized robot welds on ships, boiler walls, pressure vessels, sub sea equipment, trains, pipe lines, oil rigs, farm / construction equipment etc.

INSTANT ROBOT WELD BENEFITS: 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 are necessary 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. As the Genie plant found out with it's lifting equipment, (right) with Ed's robot process control training, optimum 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.
[] Focus on weld defect prevention and attaining minimum weld
rejects and rework.
[] Focus on weld deposition rates and the fastest possible weld speeds.
[] Reduce the influence of sales advice and provide logical cost justification for MIG equipment and consumables.

Think of the benefits of working in a manufacturing weld shop environment in which;

[] best weld practices without sales bias are established,

[] optimum robot weld process controls are established,

[] product liability concerns are reduced,

[] all the weld decision makers take a uniform, professional, practical, cost effective approach to the daily attainment of optimum, robot weld quality and productivity.

Note: As this CD program simplifies MIG weld 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, just point and click.

This training 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, technicians and operators who make weld changes, all should walk the same path to robot 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.

Click here if you need more information on this CD, Power Point Program.

[2b] The Book.

"Manual / Robot MIG 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 is an essential tool for MIG weld quality / productivity optimization. This book presents Ed's unique, process control Clock Method. The Clock method provides a simple, highly effective, easy to remember approach to the selection of optimum MIG parameters for any robot carbon steels, alloy steels and stainless applications. Read this book, answer the 160 questions and you are ready to present the robot process control training program.

[2c] The 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 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 3000 hours to develop this unique, Robot Process Control Training Program.

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

To order item 2 Click here

For those of you that wonder about the level your MIG
weld process knowledge, try this MIG test.

E-mail:

Tenneco: Ed. Tenneco has plants all over the world. We have been very enlightened by your " Robot MIG Weld Process Control Training Resources " We are slowly implementing your robot weld process control and best practice concepts to the shop floors. Tom Plummer: Tenneco. USA. 2007.

Take a look what Ed's Robot Process Control program
achieved for the Ford F-150 truck frames and Dana

E-mail:

Dana: 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 lines were producing less than 40 truck frames per-hour and the majority required extensive weld rework.

Thanks to your robot weld training programs and your process and consumable recommendations, 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. We have now implemented your robot weld process recommendations in five of our USA plants

Many thanks!
Ryan Good: A Grateful Employee.
Dana Corporation.

E-mail:

Ed. I just received your process control materials and within five minutes of skimming, I found flaws in our weld techniques. These materials will be very helpful to our organization! Thanks for your expertise and prompt service! Marcus di Sabella. Process Engineer.Car Sound Exhaust System, Inc. / Magnaflow Performance Exhaust.
Rancho Santa Margarita, CA

E-mail:

Dear Ed. These are fantastic resources for anybody engaged in welding 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. Last week I received your robot process control material, which I've been reviewing. I find it very 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 issues you address are part of our every day work.. Thank you Jose Ignacio Moreno. Spain.

Item 3. This unique self teaching training package comprises of 3 items. This "manual" MIG process control program was developed for all carbon steels, stainless, nickel steels and aluminum robot applications, welding 20 gage to any thickness.

" Manual MIG Weld Process Optimization from Weld Process Controls".

[3a] Training CD: "Manual MIG Best Weld Practices
and Process Controls"

[3b] Book: "Manual MIG including Pulsed"

[3c] DVD film: "Manual MIG Process Controls Made Simple"

Items 3a/b/c. Cost $395.

What type of logic is it to provide a welder with an $8000 pulsed MIG weld power source and then every day for the next decade watch the welder play around with the weld machine's controls?

It has to be frustrating for managers or engineers who believe in a uniform, controlled approach to weld manufacturing, to daily watch weld personnel play around with weld controls.

Many weld shops work with weld procedures and most weld shops will have variables that can influence the weld quality and productivity. The question is, with the process and consumables utilized, how will your weld personnel react to those variables?

[] Imagine a weld shop in which all the manual MIG weld personnel are aware of the reasons for weld defects and the costly weld repairs, and these individuals have been provided with this program which will give them the MIG process control capability to minimize the opportunity for weld defects.

[] Imagine a weld shop in which all weld personnel can set the most suitable weld transfer mode and instantly set spatter free, optimum MIG short circuit, CMT, STT, globular, pulsed and spray parameters for any MIG weld wire on any steel or stainless parts.

[] Imagine a weld shop in which all weld personnel are aware of the optimum MIG weld settings that deliver maximum weld deposition rates for any application.

WHEN SOMETHING OF GREAT VALUE IS COMPLEX,
SOMEONE SHOULD MAKE IT SIMPLE:

This package presents the "MIG Clock Method" which Ed developed over three decades. The MIG process control Clock Method provides a unique, simple approach to remembering the weld data necessary to attain optimum MIG and flux cored welds on any steels, stainless, alloy steels and aluminum applications. The program also provides the most comprehensive training approach to MIG "weld defect prevention"

[3a] The Training CD.

"Manual" MIG Best Weld Practices and Weld Process Controls"

A UNIQUE, ANIMATED, POWER POINT TRAINING PROGRAM REQUIRES 8 HOURS:

This is the most comprehensive, practical manual MIG training program ever developed. This unique Power Point CD, will lead your weld team in the simplification of optimum, MIG weld parameter selection for all short circuit, spray and pulsed manual applications. You will experience instant, manual weld quality and productivity improvements from this program. As this program increases the operators confidence in controlling the weld transfer modes, you will also find this program dramatically decreases the time required for MIG training.

TEACHING YOUR SELF, OR TEACHING A GROUP OF WELD PERSONNEL IN A CLASSROOM, THIS UNIQUE, ANIMATED CD POWER POINT TRAINING PROGRAM REQUIRES EIGHT HOURS. NO WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THE PROGRAM. SIMPLY POP IT IN A LAP TOP AND CLICK.
[] Setting an optimum short circuit, globular, spray or pulsed welds is made simple and the welders selects the optimum weld transfer mode for the application.

[] This training resource is the only global resource available that provides you with the reasons and logic, why you should have concerns when you utilize pulsed MIG, Inverters or multipurpose welding equipment on carbon steel and stainless
applications > 7 mm.

[] The root cause of all of your potential weld defects are graphically revealed and the practical cost affective process control resolutions are provided.

[] Weld costs are driven by MANAGERS, SUPERVISORS, TECHNICIANS AND ENGINEERS understanding the relationships between the application, the weld consumables, the weld parameters and weld transfer modes utilized. This program simplifies that relationship and provides weld personnel with the expertise necessary to attain optimum, weld quality / deposition rates on all applications.

A few hours with this unique manual MIG welder training program and the weld results are immediate.

[] No more "playing around" with weld controls.
[] Minimize costly weld defects or rejects.
[] 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 all those different gas mixes and you will no longer need that costly 3 part gas mix or metal cored wire.

What you will have is a highly competitive weld shop, in which all the weld personnel and all the weld decision makers take a uniform approach to weld process controls and all walk the same path to the daily achievement of delivering optimum, manual MIG weld quality and productivity.

What expertise do you need to present this program? Simply place the CD in a lap top, project it on a screen and let the program present itself.

For much more information on this CD Program, click here.

[3b] The Book.

"Manual MIG Process Controls"

Written by Ed Craig. (170 pages). For more Information, click here.

[3c] 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 simplification of optimum, CV MIG weld parameter selection, for all those steel and stainless applications.

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.

Items 3a-b-c. Total cost $395.

To order item 3. Click here

E-mail:
Dear Ed. I am a welding engineer working in the UK. I recently discovered your excellent website 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 from Mike.
The books and CDs arrived on Friday and I can see from the couple of hours reading I've done so far that they're full of valuable MIG and flux cored weld process control knowledge and great advice. Thanks for the wonderful website. Sincerely. Mike Harris. New Zealand.

Astec Industries. A group of of companies that have become America’s leading manufacturer
of equipment for asphalt road building, aggregate processing, pipeline and utility trenching,
Astec uses Ed's MIG and flux cored process control training resources.

FLUX CORED & WELD PROCESS OPTIMIZATION:

Item. 4.

"Optimum Manual and Automated Flux Cored Plate and Pipe
Welds from a Unique Weld Process Controls Training Package".

[Package 2 includes items a + b +c]
[4a] Training CD: "Pipe & Plate. Flux Cored. Best Weld Practices and Process Controls".

[4b] Book: "Gas Metal Arc and Flux Cored Welding"
[4c] DVD film: "Manual MIG Process Control Made Simple"

Item 4. Package Cost $395.

[4a] " Gas Shielded Flux Cored Process Controls Training CD.
Flux cored on all manual and automated pipe, structural and plate applications".

Also included in this program, MIG short circuit, STT and RMD process optimization for pipe root welds. This is the most comprehensive, practical flux cored process control training program ever developed.

API -ASME-AWS-NACE-ABS. All weld codes require optimum flux cored / MIG weld procedures, yet every critical weld that has a defect or has failed, is a weld made with a so called pre-qualified weld procedure.

What is essential to the success of any weld project, is the welder's response to the numerous variables that daily influence the welds on the shop floor or at the project.

How do your weld personnel respond to flux cored welds that will be on parts that have undersize or excess root gaps, weld joint misalignment, poor weld edge preparation, poor weld joint access, difficult out of position welds, unacceptable plate or pipe surface and ever changing environmental issues?

The welders tools to address variables and weld issues are the weld equipment and consumables utilized, combined with the welders weld process control expertise and skills.

Rather than play around with weld data, all weld personnel should have the ability to instantly change and provide optimum flux cored weld parameters to deal with the common variables in vee groove. The welders should be using the recommended weld techniques for the consumables and application, not their self taught techniques or the techniques taught by a weld instructor more comfortable with the SMAW process. It's also beneficial when the welders have been trained to be aware of the root cause of the flux cored weld defects and the weld solutions that will prevent those defects from occurring.

TEACHING YOUR SELF, OR TEACHING A GROUP OF WELD PERSONNEL IN A CLASSROOM, THIS UNIQUE, ANIMATED FLUX CORED CD POWER POINT TRAINING PROGRAM REQUIRES EIGHT - TEN HOURS. NO WELD PROCESS EXPERTISE IS REQUIRED. TO PRESENT THE PROGRAM, SIMPLY POP THE CD IN THE LAP TOP AND CLICK....

Everything your workforce could possibly ever need to know about optimizing manual / automated flux cored, and MIG root weld quality and productivity on all position pipe, plate, structural and pressure vessel welds. Flux cored weld wires covered. EX1T-1, EX0T-1. All carbon steels, low alloy and stainless flux cored wires. Wire Sizes. 0.045 - 0.052 - 1/16 - 3/32, (1.2 - 1.4 - 1.6 - 2.4 mm).

Welding a ship's plate, construction equipment, or the most complex pressure vessel or 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 always ensure minimum weld defects with maximum weld productivity.

The benefits to your self and the weld shop will be many.

[] No more weld personnel "playing around " with weld controls on code applications. The welder sees an issue that effects the weld quality and productivity and instantly provides optimum data and techniques to resolve that issue.

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

[] All weld personnel attaining the process knowledge and technique awareness of how to minimize the opportunity for common flux cored weld defects such as lack of weld fusion, weld cracks, porosity, worm tracks, slag inclusions and spatter.

[] All weld personnel with the process control 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.

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

Each flux core wire size has has three 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 multipass 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 consumable data that you will never get from a salesman.

The CD presents the training program in a simple unique manner, in which 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 the CD's 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 focussed on weld costs, you can be sure these recommendations ensure optimum weld deposition rates are always attained, dramatically improving your daily weld production

OPTIMUM PQR OR PROCEDURE DATA FOR FLUX CORED WELDS: Welding ships, trains, pipe lines, oil platforms, construction projects heavy equipment, bridges or or cranes, there is no better weld data provided.

REDUCE FLUX CORED WELD TRAINING TIME AND 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 and three days hands on, that weld personnel will produce flux cored welds that will meet any code requirement for any position welds.

FLUX CORED WELD EQUIPMENT, PROCESS AND CONSUMABLE OPTIMIZATION: If you spend any time at this site, you know that process control expertise is the missing link to process optimization. Provide practical process control knowledge and your weld personnel will immediately feel more comfortable and confident with the equipment, process and consumables utilized.

THE WELD TEAM AND CONTROLLING FLUX CORED WELD QUALITY AND PRODUCTIVITY. 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. It's time to provide the solution for your employees to take a logical. uniform approach to flux cored weld quality / productivity, and this is the most comprehensive, CD training program ever developed for the flux cored process.

This training is applicable to anyone in a plant who welds, or makes decisions on flux cored weld quality or productivity. Managers, engineers, supervisors, QA personnel and of course all weld personnel should walk the same process control path to weld process optimization.

Note: If you are ready to take a flux cored weld test, or want to step up in your career to weld supervision, or weld management, it's logical that you should fully understand the process you are going to manage.

More information on this Flux Cored CD click here.

[4b] The Book:

"MIG and Flux Cored Weld Parameter
Selection made Simple"

Written by Ed Craig. (156 pages).

For information on this book click here

[4c] DVD film.
"Manual MIG Weld Process Controls
Made Simple".

Produced by Ed Craig. (Runs 60 minutes).

Remember "a picture is worth a 1000 words. To attain process optimization from flux cored consumables you have to fully understand the MIG equipment relationships between voltage and wire feed positions for the different diameter flux cored wires. This DVD movie takes you through Ed's simple clock method for MIG weld process controls. 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.
Item.4a - b - c. Total Costs $395.

To order item 4. Click here.

Test your flux cored weld process expertise.
Try Ed's Flux Core Welding test

Welding Book Testimonials

E-mail from I C.
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. Thanks for the great web site and thanks for your very unique process control training resources.
Regards. I C Ormrod. Australia.

E-mail from Dave
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 from Larry.
Dear Mr. Ed Craig. 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 from Chris.
Good day Ed. I found your Flux Cored Welding book an excellent weld process control training resource.
Chris Stask.Welding Instructor. Camosun College.Vancouver Island BC.

E-mail. Dear Ed. Your training resources and website 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 5a."Proceso de Soldadura MIG Manual"

( MIG Made Simple in Spanish)

A Self Teaching manual MIG weld process control book (170 pages) .in Spanish.
Plus the following DVD (MIG Video ). Written and produced by Ed Craig.

[5b] The DVD FILM. English.
"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 simplification of optimum, CV MIG parameter selection, for all those steel and stainless applications.

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.

Item 5 a+b cost $195. To Order Click Here

Item 6a. The Self Teaching Book. English.

( MIG Made Simple in English)

Written by Ed Craig. (170 pages).

This is a self teaching package is focussed on the requirements of manual MIG Weld Process Controls. This book presents Ed's unique, process control Clock Method. The Clock method provides a simple, highly effective approach to the selection of optimum MIG parameters for any carbon steels, alloy steels and stainless manual / robot application. The DVD is a great process control training tool, no more playing around with those MIG short circuit or spray welds.

[6b] The DVD FILM.
"Manual MIG Weld 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 simplification of optimum, CV MIG parameter selection, for all those steel and stainless applications.

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.

Item 6a+b cost $195. To Order Click Here

REMEMBER WELD PROCESS TRAINING IS THE MOST IMPORTANT SOLUTION TO
MANUAL MIG / FLUX CORED WELDER SHORTAGES:

PROVIDE PROCESS CONTROL TRAINING AND THE BENEFITS ARE MANY: Apart from experienced weld personnel "playing around" with MIG weld controls, another problem for many manufacturers is the shortage of skilled MIG and flux cored welders. When you provide this unique process control training, you immediately improve the process confidence level in your employees. With the ability to instantly set optimum weld parameters, attaining uniform, consistent, optimum MIG / flux cored weld quality and productivity is not a difficult task.

With Ed's process control training resources, in combination with conventional, hands on skills training , it typically takes less than a week to train a none welder to handle all MIG and flux cored applications, and yes that includes all position pipe welds made to any ASME. API code requirements.

Show me a weld shop in which the young or old welders don't "play around" with the weld controls and it's time for me to retire.

The resources at this site enable MIG and flux cored weld process ownership through the implementation of Best Weld Practices and highly effective Weld Process Controls.

If you have to play around with weld controls, or look at a book to write a weld procedure or resolve weld questions, you will benefit from the Ed's
Weld Clock Method.

If you request, in less than a week, Ed will customize a weld training program for any application. Typical examples include:

[] Defect free, low dilution (<5%) ,automated, stainless, Inconel and duplex, TIG clad welds for the oil and power industries.
[] High deposition, single pass, less than <8% dilution, stainless and Inconel MIG clad welds.
[] Defect free, thick plate, all position , ceramic backed flux cored welds.
[] Defect free, high production robot welds for any applications

Phone Ed day or evening 828 658 3574. North Carolina. Eastern Standard Time.
E mail. ecraig@weldreality.com.

Ed Resolves Numerous Weld Problems with a Phone Call.
If you are looking for MIG , TIG, FCAW, SAW weld procedures or honest, practical solutions to your manual or automated, weld, corrosion, erosion, quality, productivity, design or metallurgical issues. For a small fee that starts at of $375, in a few hours using the phone and E-mail, I will resolve many of your weld issues.

If you wish me to visit your facility, I will quickly address the primary root causes of all your robot and manual your weld process issues. I will establish the required "best weld practices" and provide the requirements for highly effective "weld process controls". I will make adjustments to the robots and optimize the weld data. I will provide the necessary hands on and classroom process control training that should enable robot rework of less than 2 % and a typical weld production increase in the range of 20 to 50%. I can improve your part or robot cell design, solve your metallurgical issues or possibly create a unique weld approach for a possible patent.

For those of you who have Spanish speaking robot MIG personnel, while working in Vigo, Spain on setting robot welds Citroen / BMW / Toyota car seats, it was my great pleasure to work with one of Europe's best robot / mechanical engineers. His name is Alejandro Conde ( Alex). We were a hell of a team and attained robot weld quality and productivity rarely seen in USA auto / truck plants. For those interested, Alex translated my robot weld process control book into Spanish.

Ed is the one in the middle.

In the welding industry, it's "impotant" to
have a sense of humor. Keep Smiling.

GM - FORD - HARLEY - DANA - MAGNA - TENNECO - VOLVO - TOYOTA - HONDA - IMPERIAL OIL - COMBUSTION ENGINEERING - IODINE - CATERPILLAR - JOHN DEERE - MERCEDES - DOW CHEMICAL - BABCOCK - ABB - GENERAL DYNAMICS - GE - VW - TEXTRON - INGERSOLL RAND - ESSO - IMPERIAL OIL - CAMERON are just a few companies that utilized Ed's weldprocess control services or training resources.

Daily, over the phone or by E mail, Ed provides weld process quality / productivity solutions for a flat fee of $375. (Visa / MC) Contact Ed.

Phone Ed day or evening 828 658 3574. North Carolina. Eastern Standard Time.
E mail. ecraig@weldreality.com.

To order any materials you can also call Ed's wife Janet,
Phone 828 658 3574, keep your voice soft
as we try not to upset our puppy:

E-mail.
Ed. I wanted you to know I have just announced that I am leaving my company. I am going to work for a robot weld integrator. I will be the head of the welding applications department and will be specifying process, wire, training, techniques, 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 information, books, CDs and your welding passion that you passed on to me. They are what got me started in the quest for more real world weld knowledge. In my new position I will be able to do this full-time and could not ask for a better position at this point in my career.
Warmest Regards. Jeff Winter. Ont. Canada.

It's amazing how many MIG - Flux Core - TIG weld procedures
have weld data that is not optimum for the intended application.

Use Ed's process control resources to optimimize your PQR's and weld procedures and
for the most simple method to develop ASME - API - AWS weld procedures check out;

To visit WPSAmerica click here.

TIP-TIG The world's most effective weld process.

Return to www.weldreality.com home page.

All Welding and Steels Programs: / Ed's Welding Books, Manuals & CD Training Resources

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Welding Books

Welding CD's

MIG Weld and Flux Cored. Weld Best Practices and Process Control Training Resources:

Welding Book Testimonials

MIG Weld and Flux Cored.
Weld Best Practices and Process
Control Training Resources: