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

Ed's Craig's MIG & Flux Cored Weld Best Practices
and Weld Process Control Training Resources.

Optimum Manual and Robot Best Weld Practices and Process Controls
cannot be implemented without weld process and application expertise.

Ed Craig has optimized weld processes for 50 years.

 

Interested in your level of Flux Cored weld process control knowlege?

Try Ed's Flux Cored weld test.

A WELD SHOP CAN CREATE AN EFFECTIVE WELD TEAM AND PRODUCE CONSISTENT, OPTIMUM WELD QUALITY IF THE TEAM FULLY UNDERSTANDS THE REQUIREMENTS FOR BEST WELD PRACTICES AND PROCESS CONTROLS. WELDERS WILL NOT HAVE TO PLAY AROUND WITH THE MIG - FLUX CORED WELD CONTROLS, IF THEY ARE PROVIDED WITH THE CLOCK METHOD WHICH SIMPLIFIES THE SELECTION OF OPTIMUM WELD PARAMETERS. MANAGERS - ENGINEERS AND SUPERVISORS SHOULD APPRECIATE A METHOD THAT SIMPLIFIES WELD COSTS. IN AN INDUSTRY THAT PUTS ITS FOCUS ON WELD SKILLS: The ability to instantly optimize manual or robot MIG or flux cored welds is derived from a combination of weld process control expertise - weld best practices - weld application and alloy expertise and with manual welds, the required skills. My name is Ed Craig. Welcome to weld Best Practices - Process Control training resources that will benefit any weld shop or project. More than thirty years ago, I started to develop the Clock Method, a unique MIG - Flux Cored Weld Process Control and Best Practice training method that provides the requirements for both optimum weld quality and productivity.. The Weld Clock method simplifies the requirements for optimum weld quality - productivity with MIG and Flux Cored. With a few hours with one of my training programs, irrespective of the weld experience any individual will have the ability "without playing around with the weld controls" to instantly set optimum weld parameters for any MIG - Flux Cored application. The welds produced will always attain their full quality potential and the weld personnel who learn these program will have the unique expertise necessary to know the full weld productivity potential of each weld and also the costs of any weld produced. In the last five decades, I have resolved manual and robot weld issues and established Weld Process Controls and Best Weld Practices in more than a thousand companies in thirteen different countries. I have four weld patents. I spent seven years TIG welding in a nuclear research facility. I was the Weld Manager in a large US ship yard and the Robot Weld Training Manager for ABB one of the world's largest robot companies. I was the weld Training Manager for Praxair and the Weld Equipment - Marketing Manager for Airgas the world's largest supplier of weld equipment. Picture: Ed in Ohio as a process control consultant providing a MIG Weld Best Practice - Process Controls work shop to 60 participants from 5 different countries. Many of you will know me from the 18 years I wrote the QA weld column in the USA. Weld Design and Fabrication magazine or perhaps you read one of my thirty plus published articles on the Simplification of manual and robot MIG / Flux cored weld process controls. If you have a Machinery Handbook gathering dust on your shelve, I wrote the weld section and have written three books on Weld Best Practices and Weld Process Controls. If I can make a dumb, blind robots consistently produce the best possible weld quality - productivity, think of the possibilities of what any weld shop could achieve if all weld personnel are provided with Best Weld Practices and Weld Process Controls Expertise. A Few of my robot weld quality - productivity improvement projects include. FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES - HARLEY BIKE FRAMES - VW BEETLE & MERCEDES SEAT WELDS - ROBOT WELDS ON WORLD'S LARGEST CATERPILLAR TRUCKS - FIRST TO SET ROBOT WELDS ON BOILER TUBES TO HEADER WELDS - FIRST TO SET ROBOT CLAD WELDS ON BOILER WATER WALLS - FIRST TO SET ROBOTS WELDING 40 inch PIPE - FIRST TO SET ROBOT WELDS ON AN OIL RIG - FIRST TO SET ROBOTS WELDING ALUMINUM GOLF CART FRAMES.

Weld Career Prospects should be great, when working in a Confused Weld Industry. If you have worked in a weld shop, you must have watched weld personnel "play around" with the 50 year old MIG weld process controls, and you must have noted the daily inconsistent weld results and process confusion throughout the shop. If you have worked in a weld shop, you must have seen unqualified weld salesmen giving advice to the weld supervisors, technicians, engineers or plant manager. If you have worked in a weld shop, you must have wondered why there were so the many different power sources, and weld consumables used, and were 6 different MIG weld gas mixes necessary? If you worked in a weld shop you must have wondered how much money was spent each year with grinding wheels and how much labor costs was wasted on necessary grinding and weld rework. If you worked in a weld shop you must have met supervisors, inspectors and managers that knew nothing about three important subjects called Best Weld Practices - Weld Process Controls and Weld Costs. The quickest way to provide cost reductions in a weld shop or simply fast track your welding career in this confused global industry is provide something that is scarce. Have the logical ability to provide Best Weld Practices and Weld Process Control Training and you will enable immediate weld quality and productivity improvements with dramatic weld cost reductions. If you want to teach your self, or you wish to provide Weld Best Practices - Weld Process Control Training for others, you will find that the following resources are what you need for attaining optimum MIG and Flux Cored welds with any global Manual - Automated or Robot application. The following is a "summary" of the MIG & Flux Cored Weld Process Control Training or Self Teaching Resources. Scroll down for the complete programs and order information.

 

REFERENCE THIS WEB SITE: I established www.weldreality.com in 1997, this was before Google was a company, the web building technology was crude and my web site building expertise and control of the English language was and still is laughable. It may not be a sophisticated looking web site, however its a site full of weld reality and practical information and its also the world's largest MIG - FCA weld Best Practices - Process Control Web or Blog site.

You will note there are no weld sales advertisements at the site and there is a reason. I belief growth in the weld industry has for decades been retarded by this industries' reliance on sales influenced weld advice.

I believe to effectively manage any weld process, weld decision makers should strive to understand the fundamentals of Best Weld Practices and Weld Process Controls. Also its time for weld shop management, engineers and supervision to cut the umbilical cord between them and the companies that make and sell weld equipment and consumables. Weld quality - costs benefits will come when management, engineers and supervisors "take ownership" of the manufacturing processes that create the profits for their companies.

 

A summary of the weld process control and best practices resources: Item 1. The Book. "A Management - Engineers Guide to MIG - Flux Cored, Weld Quality - Productivity and Costs. Written by Ed Craig. With 600 pages this the most comprehensive and practical book ever written on the MIG and Flux Cored Weld Best Practices and Weld Process Controls. Also includes Ed's MIG Process Control DVD. Item 2. "Robot MIG Weld Best Practices and Process Control Training Resource"includes; For over 30 years Ed has been developing methods that simplify the selection of optimum MIG weld data and the requirements to achieve the highest possible robot weld quality and productivity. Ed worked for ABB as the North American Robot Weld Manager. He introduced ABB to the world's first Robot Weld Best Practices - Weld Process Control Training program which he had been developing for two decades, a program he has continued to evolve. While you ponder your weld automation investment costs and wonder how much the daily weld rework and loss of productivity is affecting your companies profits, the bottom line is the robot companies have not helped you and you don't want another sales rep coming in the door. You need solutions to your weld quality - productivity issues. When you invest a few hundred dollars for this program and slip the power point CD into your computer you will be getting the expertise of an individual that has spent 50 years on the subject and took > 3000 hours to develop that CD program. Item 3. "Manual" MIG Weld Process Controls & Best Weld Practices Training. Manual MIG weld personnel may have to deal with MIG Short Circuit - MIG Spray Transfer - MIG Globular Transfer, Pulsed MIG - MIG RMD - MIG STT - MIG CMT, yet the majority of global skilled manual MIG weld personnel lack process control expertise and when trying to set different welds will too frequently "play around" with the weld controls. FACT: If I visited or skyped your plant, and asked the top five experienced weld personnel in your organization the following fundamental questions, you know I am going to get some crazy answers; [a] With an 0.045 (1.2mm) carbon steel wire, and an argon - 20% CO2 mix, on that digital wire feed control provide the inch/min or m/min, start point for MIG Spray Transfer. [b] Welding that common 1/4 fillet, and the 0.045 wire feed is set at at 400 inch/min (1 o'clock) position. Without reading a book or asking a salesman, provide the weld deposition rate you will achieve (arc on time 30 minutes/hr) and what will be the cost per-foot of weld be if your weld wire cost $1 lb. and the gas cylinder is $40? [c] When welding a 1/4 (6mm) fillet weld, explain why the lower cost CV MIG equipment will produce superior weld manual and robot weld quality than a more costly pulsed MIG power source? [d] You change your MIG gas mix from an 90% argon - 10 CO2 mix to a common 80% - 20% CO2 gas mix, what weld parameters will you have to change and why? Maybe you are one of those managers, engineers, technicians or supervisors who are fed up with purchasing over priced, ineffective electronic Pulsed MIG equipment . Perhaps after trying so many different gas mixes you are finally figuring out your MIG gas selections options are in reality more of a sales influenced gas commodity game. Perhaps you are wondering why your welders can't produce optimum weld quality without a grinder. Or maybe you are wondering why the welders are using costly Metal Cored and flux cored wires on applications that for decades have been successfully welded lower cost MIG wires. Or perhaps you are a rational individual that knows the solutions to your weld problems is not going to come from bells and whistles weld equipment or three part gas mixes, its going to come from between the ears of all those involved in weld decisions. Note: As Ed simplifies these programs, no MIG or flux cored weld process expertise is required to present any of the programs. Scroll down for more info and order requirements. Every Code Weld that has required weld rework or every code weld that has failed, were welds made with the data from a so called, "optimum, pre-qualified weld procedures". Either the person who wrote the procedures screwed up, or the managers who controlled the welders did not manage. When weld faults are revealed, the management focus is often on the “manual skills” of the welder responsible and there is typically minimal consideration given to the following factors;   [1] inadequate weld procedures, [2] lack of Best Weld Practice knowledge. [3] lack of Weld Process Control Expertise, [4] lack of focus on the numerous variables that daily can impact the weld quality and productivity. [5] Lack of awareness of the weld issues generated by the weld equipment - consumables - process utilized. All of these considerations and much more are covered in Ed's Training programs. IT'S RARE TO FIND A MANUFACTURING PLANT OR WELD FACILITY IN WHICH THE QA PERSONNEL ARE TRAINED TO PREVENT WELD DEFECTS RATHER THAN SIMPLY FIND THEM Item. 4. "Manual - Automated Flux Cored, Best Weld Practices Process Control Training" How would you like to have the ability to do the following? Walk into any global pipe shop and for the pipe ROOT welds, depending on the weld position, instantly set a MIG STT - MIG RMD - MIG Short Circuit. Then with either Pulsed MIG or flux cored for the fill passes instantly (without playing around) provide the best practices and all the data necessary to attain optimum welds. (Note optimum welds with these two weld processes, means welds with defects that will be influenced by the weld processes, rather than by the weld personnel using the processes. YOU MIGHT ASK IN A SHIP YARD "WHO IS RUNNING THE SHIP" You decide to take a job managing welding in one of the few remaining North American ship yards. This yard has a contract to build oil tankers or air craft carriers. As with any ship yard the behind the glass wall management will spend too much of their time with accountants and be isolated or ignorant from the real world weld issues. The hands off management will be content with hands off engineers who typically will not be given the ownership or accountability for the daily weld quality - productivity. The supervisors cannot supervise processes that they have never fully understood. The weld rework costs will always be way over budget and to add to the insult, the daily weld production rates will typically the lowest in the weld industry. Mean while as long as the welders have access to grinding wheels they are happy. The root cause of the weld issues in many (not all) ship yards or in many plants with a large weld work force are simple. [a] Lack of ownership. [b] Lack of accountability. [c] Lack of weld process controls and best practices expertise. If you presented this Flux Cored Process Control - Best Practice Training Program in the environment mentioned. The results would be dramatic. Finally without playing around with the weld controls, all the weld personnel would know how to attain optimum flux cored root welds with those ceramic root gaps that daily vary from 3 to 12 mm. With the all position, vee groove plate welds, the ship yard welders would now produce a weld quality and productivity that has never been attained by the yard. YOU HAVE TO SEE THE HUMOR WHEN YOU READ A WELD JOURNAL ARTICLE ABOUT SHIP YARD MANAGERS CONSIDERING THE USE OF A HYBRED LASER OR ROBOTS WITH PULSED MIG EQUIPMENT FOR SOME OF THEIR APPLICATIONS, WHEN THE REALITY IS FOR DECADES THESE SAME MANAGERS HAVE LACKED THE EXPERTISE AND ABILITY TO OPTIMIZE THE TWO SIMPLE WELD CONTROLS ON A REGULAR MIG POWER SOURCE: After you train the manual welders and receive your weld bonus, you then take on the task of improving the yards automated Flux Cored applications, Again using this program, you take the yard to a new level for automated weld quality and productivity. You ensure when you provide the training work shops that all the weld personnel in the yard including the managers, supervisor, engineers, QA personnel take the training. Within a few months everyone in the yard is on board with the requirements necessary to daily attain the best possible weld quality and productivity. Fed up with the cold winters and with the ship yard weld challenge behind you, a new job opportunity is presented where you will be in charge of welding at one of the world's largest manufactures of construction and farm equipment. In this company the management and weld shop floor culture is deeply ingrained. Your biggest issue is the management wants weld cost reductions but these same managers and their employees fear change. Its also no surprise in this company that salesmanship has had too much influence on the plant's daily weld decisions. You work out that the plant and two of its sister plants are loosing approx. 5 to 6 million dollars though weld rework and poor weld productivity. You put the MIG and flux cored Best Practices training programs into effect. Within a few months you have a work force that is no longer concerned about change and they no longer play around with their weld controls. The supervisors and engineers and managers no longer have ask a salesman for weld advice and the QA department now has the unique ability to prevent weld defects rather than just complain about them. To rise in this this industry you will have to address the following. [] Do you want to develop professional work force or will you continue to work with weld personnel who have to "play around" with the Gas Shielded Flux Cored weld controls? [] Weld results are a team effort. To create the weld results you know are possible, you are going to have to create a cohesive weld team in which all involved walk the same path to daily attain consistent weld quality and productivity. [] You want to create a weld shop which no longer opens the door for advise from the inexperienced sales rep. A weld shop in which weld equipment is uniform and without bells and whistles. A weld shop that has few weld consumables and no more than three weld gas mixes. [] In your weld shop, all weld personnel will be aware why weld flux cored weld defects occur and they will be able to instantly provide weld solutions to the many variables that influence the weld quality - productivity? [] Finally in your organization as all are on board with the requirements necessary for weld optimization you cut down on the time wasting, unproductive meetings that have gone on for years. I took over 3000 hours to develop this CD Power Point program, so please don't call me and ask for a discount. Note: Also provided with this flux cored program is optimum MIG pipe root data for the STT - Short Circ - RMD and the unique data required for flux cored root welds with steel or ceramic backing. PLEASE NOTE: Again to encourage managers, no flux cored weld process expertise is necessary to present this unique CD Power Point program. For more details and order info, scroll down. Item 5a."Proceso de Soldadura MIG Manual" This is the item 3: MIG Process Control Made Simple. Book translated into Spanish, Item 6a. "The Self Teaching Manual MIG Process Control Book and Video". (English). For more details or to order, scroll down.

 

 

 

Item.1. The Book:

"A Management & Engineers Guide To MIG - Flux Cored
Weld Quality - Productivity and Costs"

This order includes two items. 1 - 1a.

When management and engineers decide to step up to the plate and take ownership of the welding processes that are responsible for their profits, this 600 page book is the first step. This is the most comprehensive book ever written on the requirements necessary to establish MIG - Flux Cored Weld Best Practices and Weld Process Controls.

Written by Ed Craig.

MIG AND FLUX CORED WELDS ACCOUNT FOR MORE THAN 85% OF THE WELDS PRODUCED EACH DAY. WELD MANAGERS, SUPERVISORS OR TECHNICIANS DO NOT REQUIRE THE ABILITY TO WELD, HOWEVER THESE INDIVIDUALS SHOULD KNOW HOW TO MANAGE, OPTIMIZE AND OWN THE WELD PROCESSES CRITICAL TO THEIR ORGANIZATION.

In a global industry in which weld personnel have for five decades "played around" with MIG weld controls, an industry in which weld sales advice often seems more relevant than weld reality, it should be no surprise to find the common day to day weld quality and production issues rarely get resolved and that will be the status quo till those that manage the weld shop understand the process control and best practices necessary for weld optimization.

Note. This book shows the importance of implementing Best Weld Practices and the numerous cost and quality benefits of Weld Process Controls. If you think your weld personnel have this expertise, ask 5 welders in your plant where spray transfer starts on the wire feed control with the world's most common 0.035 - 0.045 (0.9 - 1.2mm) MIG wires, you will get five different answers.

Item. [1a]. The DVD FILM.

"Manual MIG Weld Process Controls Made Simple".

Produced by Ed Craig. (Run time 60 minutes).

If a picture is worth a 1000 words this video is worth a million. This DVD movie is a great visual tool in presenting the Clock Method which simplifies optimum MIG Parameter Selection for any steels alloy steels and all 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. If you MIG weld with robots be sure to check out item 2..

Items 1 - 1a. Cost. $245 plus shipping. ( $20 USA & Canada or $50 elsewhere)

 

E-mail.
2007: Ref the Weld Management Book:

Hello Ed. I recently purchased your "Management and Engineers Guide to MIG Welding". The book is everything I had hoped it would be and then some! Thank-you Ed for having the motivation and courage for your web site and the information you provide. I have not yet come across an opinion that I did not share or a concept I did not admire. ”The more I learn from you, the more I find there is to learn.” That is what makes welding exciting. Your weld process knowledge combined with your personal opinions (which I find hit the nail on the head every time) has made this book one of the best teaching and training tools I have seen to date. Worth every penny, thanks Ed.

Fraser Rock. Weld Engineer. Hydroform Solutions. Ontario. Canada.

E-Mail.
Ed your Management MIG book is awesome. It is much more than I expected. I look forward to speaking with you again and possibly meeting you at the next TipTig workshop in Philadelphia.

Tony Pasqualetto pasq@shaw.ca

E-Mail.
I received your book "A Management & Engineers Guide to MIG Weld Quality, Productivity and Costs" Thank you I shall be pleased to learn about MIG welding. I am 33 years old from north-east Italy. I work as a mechanical designer in a company that designs and manufactures rolling mills all around the world. All the welded structures built are heavy parts made in carbon steel plates, welded almost always by multi pass manual MIG welding. Engineers and project managers in our technical office spend a lot of money and time buying expensive weld calculation software and complying to the confusing ISO-EN standards, then we have the advice of the so called weld consultants and weld associations. The bottom line is most of us had absolutely no idea about how the MIG process works or how to recognize a good or bad weld procedure. With your book I finally have found a logical solution to understanding and controlling the MIG process.

Regards. Oscar Cavezzan Italy.

E-Mail,
Ed. First let me say that I regularly consult your Management MIG Process book. Thank you for all the cool weld info I feel that I am now in control of this process. Your section on MIG wire stick out extension and attaining the highest possible weld deposition rates and fastest robot weld speeds was outstanding. This section alone has dramatically impacted and improved my career.

All the best mate. Nick Cooste Australia.

Ed set the Mercedes Car Seat Robot Welds in Spain.

THE FOLLOWING TRAINING PROGRAM IS ABOUT ROBOT MIG WELD OPTIMIZATION:

As many of you are aware, in the auto - truck industry the daily robot MIG weld quality and production often leaves much to be desired and extensive weld rework is considered normal. For those ready to implement change, the following resources will provide a great opportunity for weld quality - productivity improvements with dramatic cost savings:

[a] The average global, Robot MIG Weld Production Efficiency is approx. 60% of it's potential.
[b] The average Robot Weld Rework is in the range of 10 to 40%.
[c] The average Robot Down Time per-shift which is approx. 45 minutes.
[d] The majority of manufacturing companies that use robots have never attained the weld
quality and production potential from their robots.
[e] The majority of companies using arc welding robots do not have personnel qualified to
establish Best Weld Practices or qualified to make weld changes.
[f] Many of the robot MIG welds that daily pass visual inspection would with internal weld evaluation, reveal lack of weld fusion and other unacceptable weld defects.
[g] There are few plants in which you will find a manufacturing manager or weld supervisor that can in a few minutes provide you with the real world cost per foot of their most common weld.

Many robot welds are initially set by robot integrators who have extensive robot programming expertise but generally lack the weld process control expertise necessary to enable maximum Robot Weld Efficiency with minimum weld rework and robot down time. Adding to the typical plant's poor weld efficiency and unnecessary weld costs, is the vast majority of manufacturing managers - engineers who purchase the robots lack
expertise on the requirements for robot weld quality and production optimization.


FACT: THANKS TO THE INEXPERIENCED HUMANS THAT ESTABLISH THE INITIAL ROBOT WELD PROGRAMS, THE MAJORITY OF WELD ROBOTS WILL UNDERACHIEVE ON THEIR FIRST DAY ON THE JOB, AND THEN THANKS TO
THE UNQUALIFIED PERSONNEL THAT WILL DAILY OPERATE AND MANAGE THEM, THE ROBOT MIG WELD QUALITY AND PRODUCTIVITY WILL OFTEN RAPIDLY DECLINE:




FACT: It's a reality that many companies will purchase two robots to produce weld production that could be attained from one robot.

FACT: The daily logged "Robot Down Time" in many plants is often mostly management fiction and the manual welders doing the robot weld rework are too often considered an acceptable cost function for the robot welded parts.

FACT: In too many plants, once the new robots are installed, the unqualified robot personnel will daily make weld process changes to welds that were supposed to be pre-qualified (by under qualified robot integrators).

ROBOT PROCESS ERROSION: The daily never ending weld changes in the robot cells, typically add to the weld rework problems and the robot weld production and quality usually erodes. It's important to note in this industry few robot welds have internal weld evacuation, If they did they would have to stop making parts.

Those managers, engineers and technicians who desire change should be aware of the opportunities they have with the following training resource. From robot welds in a car plant or robot welds in a Nuclear plant, this program will enable dramatic robot weld quality and productivity improvements and substantial cost savings for any company.

 

Item 2 The Robot Program.

Robot MIG Weld Process Control Training.

Developed by Ed Craig.

This order contains three items 2 - 2a - 2b.

This easy to present program is without question the world's most effective Robot Weld Process Control Training Package. This unique program simplifies the requirements for robot weld quality - productivity optimization. The program was developed for all robot steels, alloy steels, stainless and aluminum weld applications from 20 gage to any thickness.

Item [2] The CD Power Point program simplifies all the Best Weld Practices and Process Control requirements necessary to attain consistent, optimum Robot MIG Weld Quality & Productivity with any application. Ed took over 3000 hours to develop this unique training program, (it's also a great self teaching program for those looking to improve their careers).

Item [2a] The Book: "Manual and Robot MIG Weld Process Controls"

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

Total Cost for items 2 - 2a - 2b. $395 plus shipping. ( $20 USA & Canada or $50 elsewhere)

Description of item [2] The Robot Training CD Power Point Program:

"Optimum Robot MIG Weld Quality & Productivity through
Robot Weld Best Practices and Weld Process Controls.

This CD Power Point program was developed by Ed Craig and its updated each year. It will take approx 14 classroom training hours to present this program and no weld process control expertise is required to present the program.

Irrespective of the carbon steels, low alloy steels, stainless or aluminum applications being welded, this program deals with all the Weld Best Practices - Process Controls necessary to attain optimum, consistent robot weld quality - productivity. The program also deals with the primary root causes and solutions for Robot Down Time and the cause and solutions for Robot Weld Defects. If you have a problem that impacts your robot weld quality - productivity you can call a team meeting and deal with frustration or provide all those involved with robot weld decisions with a resource that puts all the team on a single path to resolving robot weld issues and providing consistent optimum weld quality and productivity.

PLEASE NOTE. I SIMPLIFY THE WELD PROCESS CONTROL PORTIONS, SO THAT
NO WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THE PROGRAM.

By the way I started solving MIG issues in 1962 and 50 years later i am still solving many of the same MIG problems. I have assisted over a 1000 companies in 12 countries and enabled the plants I dealt with to consistently attain optimum robot MIG, TIG, Plasma, SAW and Flux Cored weld quality and productivity. In the last two decades I have resolved numerous Motorman - Fanuc - OTC - Cloos - Panasonic and ABB robot weld quality and productivity issues.

FACT: Some managers especially at the Big three and Tier One - Two auto - truck companies actually believe that when their operators go for robot training they are getting the training necessary that enables optimum weld quality - productivity.

Operating a robot is a low skill set. Robot program training is a high skill set,. Robot weld process control training should be given to the employees who do the programming and to those that have an opinion at the robot meetings. The weld training that robot operators require, is provide them with the ability to recognize the differences between a good weld versus an unacceptable weld.

E-Mail.
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 MIG
welding lines were producing less than 40 Ford F-150 truck
frames per-hour and the majority required extensive weld rework.

Thanks to your Robot Weld Process Control Training program
and your process and consumable changes, the robot weld
results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames per hour. We daily attain our average goal of one frame per-minute. We had two recent weld audits. One weld audit had a total of two failures,
and the 2nd weld audit was the first 100% pass weld audit in the history of the Ford F-150 line. We have now implemented your robot weld process recommendations in five of our USA plants.

Many thanks! Ryan Good: A Grateful Engineer and a grateful DANA Corporation.

Note The DANA corporation is a tier one supplier and world leader in the supply of drive line products (axles, drive shafts, and transmissions) and power technologies for light- and heavy-duty vehicles. DANA employs approximately 22,500 people in 26 countries and in 2010 had sales of $6.1 billion.


E-Mail: Hello Ed. . In the past I purchased your MIG welding training resources for both Caterpillar and more recently purchased your Robotic MIG training package for Elgin Sweeper Company here in Illinois. Ed your programs worked wonderfully at Caterpillar. We were very successful after implementing your best practices and process control training. Thanks to your training resources and equipment and consumable recommendations, our manual and robot MIG weld quality - productivity results are now outstanding. All the best. Joe Cukierski…Weld manufacturing engineer. Elgin Sweeper Company.

Ed established and influenced the robot MIG process control
data that is used to weld the world's largest trucks.

E-Mail. Ed as you know Tenneco has plants all over the world. We and especially Monroe Shocks which is one of our companies have been very enlightened by your " Robot MIG Weld Process Control Training Resources.

Regards. Tom Plummer: Tenneco. USA. 2007.

E-mail. Hello Ed, I wanted you to know I have just announced that I am leaving my company. I am now working 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 weld process control information in your books - CDs and your welding passion which you passed on to me.

Warmest Regards. Jeff Winter. Ont. Canada.

OPTIMUM ROBOT MIG WELD QUALITY & PRODUCTIVITY "THIN PARTS".

From a product liability perspective, it's ironic that the majority of so called visually acceptable robot MIG welds would with an internal weld evaluation reveal lack of weld fusion or other internal weld defects.

When robot welding gage applications, avoiding weld burn through, minimizing distortion and attaining consistent weld fusion with small welds are common issues.

This one of a kind robot weld process control training program provides instant resolutions to all the primary root causes of unacceptable weld quality, weld rework and robot down time.

When robot welding thin gage welds you can utilize six common weld transfer modes, MIG RMD - MIG CMT - MIG Short Circuit - MIG Globular - MIG Low Spray, or MIG Pulsed. Using this program, you will not have personnel "playing around" with the weld data. As this weld data is supplied by North America's leading robot weld process controls expert, you will note an instant dramatic reduction in your robot down time and will see immediate improvements in both the weld quality and productivity.


OPTIMUM ROBOT MIG WELD QUALITY & PRODUCTIVITY ON "THICK PARTS".

When Ed asked to establish the weld robot weld data for the world's largest trucks, an application that had welds on parts 1/8 to 8 inch thick, he astounded the robot engineers when he said "all the welds could be made with three simple settings".

Keeping robot programs simple is easy when you know the optimum data for the wire size and weld transfer mode.


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 for any metal and application,
[b] provide weld settings that ensure the highest possible weld deposition rates delivering
the fastest possible robot weld speeds.
[c] eliminate robot down time,
[d] enable the lowest possible robot weld rework,
[e] provide instant resolutions to all the primary variables that daily impact the robot weld quality or production,
[f] create a uniform weld shop environment that enables the lowest weld costs and reduces product liability concerns.

Ed in (photo), set the robot, aluminum frame welds on the golf cart he was given to drive around the ship yard.
In this ship yard he taught the welders how to optimize the manual - auto flux cored welds on Oil Tankers. For those interested, the annual weld cost savings was over 4 million dollars.

A FUNDAMENTAL POINT ABOUT MIG PROCESS
EXPERTISE & WELD OPTIMIZATION.

Is there a value to weld process control knowledge and the implementation of best weld practices in an organization that annually makes millions of dollars from its MIG welded parts? This is a question I should not have to ask, yet it's a question many managers give minimum consideration to. The following MIG weld process control questions should show you there is value in weld process expertise.

If you asked your most experienced robot personnel the fundamental (link) weld process questions below and they don't know the answers, ask your self this. Why have you invested f thousands or millions in robot weld equipment without providing the necessary robot weld process control training for your employees?

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

Note: Ed is the first person to write a book on attaining high speed, high deposition automated MIG welds. He also developed a patent for MIG high deposition welding gage parts and a patent for high deposition inconel / stainless clad welds on water wall boilers. Ed 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. In 12 countries Ed has optimized robot / manual welds on cars, truck, ships, boiler walls, pressure vessels, sub sea valves, trains, pipe lines, oil rigs, farm / construction equipment etc.


INSTANT ROBOT WELD BENEFITS:
Bring all your weld decision makers to a training room. Place this CD in a laptop. Project the program to the screen. In a few hours everyone has the necessary robot MIG data to establish Best Weld Practices and implement Weld Process Controls.

As the Genie and Sky Trak plants found out with their lifting equipment, (right), with Ed's manual and robot process control training programs, optimum weld results are immediate and the weld cost benefits are many.




THIS PROGRAM ALSO CUTS THROUGH THE TOO COMMON GLOBAL BS THAT DAILY INFLUENCES THE CHOICE OF WELD EQUIPMENT AND WELD CONSUMABLES. IF YOU WANT TO GET AWAY FROM ELECTRONIC BELLS AND WHISTLES AND RIDICULOUS THREE PART GAS MIXES, THE INFO YOU HAVE BEEN LOOKING FOR IS RIGHT HERE.

Ed in the robot cell demonstrating to employees at VIZA, one of the largest car seat (Mercedes, VW and Citroen) manufactures in Spain, what a waste of time and money the Miller Axcess Power source and the ridiculous Palm Pilot was.

Years previously at this company he had recommended they purchase the less costly, superior performing Miller Delta Weld equipment and this was one of the prime reasons this company was an outstanding European success. As with most companies the sales influence in time erodes the engineering controls.

This training program which was given to VIZA 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.




Description item [2a] The Book.

"Manual / Robot MIG Process Controls"

Written by Ed Craig. (170 pages).

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. With this book you will learn the unique, weld process control "Clock Method" which provides a simple, highly effective, easy to remember approach to the selection of optimum MIG parameters for any manual - robot carbon steels, alloy steels and stainless applications. Answer the 160 questions and you are ready to present the robot process control training program.



Description [2b] The DVD film.

"Manual MIG Process Controls Made Simple".

Produced by Ed Craig. (Runs 60 minutes).


When training, a video is worth a million 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 2000 hours to develop this unique, Robot Process Control Training Program.

Items 2 -2a- 2b. Total cost $395 plus shipping. ( $20 USA & Canada or $50 elsewhere)

 

Ed's Robot Process Control programs have been used on Volvo Truck Cabs,
Harley Bike frames, Corvette bodies, Ford F-150 trucks and much more.

 

E-Mail. Ed. I just received your process control materials and within five minutes of skimming through your materials I found flaws in our exhaust weld shop practices and 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. Ed. Your process control training resources are fantastic for anybody engaged in weld 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, I believe you set the Johnson control VW Beetle car seats in Mexico. Last week I received your robot process control material, which I've been reviewing. I find it your program very cost effective and practical. Your approach to weld process control is unique and it certainly works. In reading your materials, it seems like you have been in our company as most of the issues you address and resolve are part of our every day work. Thank you Jose Ignacio Moreno. Spain.
.

 

Item 3. "Manual MIG" Weld Process Optimization through
MIG Weld Best Practices and Process Control Expertise"

Developed by Ed Craig.

This order contains 3 items, 3 - 3a - 3b.

The "Manual" MIG weld process control program was developed for optimizing all carbon steels, alloy steels, stainless, duplex and aluminum MIG applications on 20 gage to any thickness.


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

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

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

Items 3 - 3a - 3b. Total cost $395 plus shipping.
(Shipping, $20 USA & Canada or $50 elsewhere).

[3] The Power Point Training CD.

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

This program requires a minimum of 12 hours to present and remember the person who presents it requires no expertise on the subjects:


MANUAL MIG PROCESS OPTIMIZATION:

What type of process logic is it to provide welders with a $6000 - $12000 pulsed MIG weld power source and then every day for the next decade watch those welders "play around" with the weld controls? It has to be frustrating for managers or engineers who believe in a uniform, controlled approach to manufacturing to daily watch manual weld personnel deliver inconsistent weld quality and productivity results.

Most weld shops have to daily deal with variables that influence their manual weld quality and productivity. Mill scale changes with each batch of steel, surface contaminates are common and poor part fit is a common disease in too many weld shop.

Ed took > 3000 hours to produce this program which has evolved over three decades and without question this is the most comprehensive, practical and unique Manual MIG Process Control - Best Practices training program ever developed.

This manual program provides Best Weld Practices and simplifies Optimum Weld Parameter Selection for all MIG Short Circuit - Spray - Pulsed - STT - RMD - CMT applications.

FACT: After the few hours required for this presentation, you should expect instant weld quality and productivity improvements. As this program increases the weld operators confidence in optimizing and controlling the weld transfer modes for any application, you will find this program also dramatically decreases the time required for new employees to undergo MIG training.

FOR THOSE MANAGERS WORRIED ABOUT THE SHORTAGE OF MIG WELDERS: Hopefully by now you realize that weld skills are only partial requirements for weld process optimization. Once you provide the missing link in your weld shop, which is the lack of Weld Best Practice and the lack Process Control expertise the results are impressive and instant. As for the concern for finding MIG welders please note;

Take a person who has never welded and with this program and forty hours of hands on training you can make that person into a professional MIG welder capable of consistently producing optimum MIG weld quality and productivity on any MIG application.

[] Imagine a weld shop in which all the manual MIG weld personnel are aware of the reasons for weld defects and these individuals have the MIG Best Practices and Process Control expertise necessary to minimize the opportunity for weld defects.

[] Imagine a weld shop in which all the weld personnel including supervisors and inspectors have the ability to set the most suitable weld transfer mode and instantly set spatter free, optimum MIG Short Circuit, MIG CMT, MIG RMD, MIG STT, MIG Globular, Pulsed MIG and MIG Spray parameters for any weld, any wire size or type on any application, and do this without looking at a note pad or a computer.

[] Imagine a weld shop in which all the weld supervisors and managers understand the cost of any weld produced and all the weld personnel are aware of the optimum MIG settings that will deliver maximum weld deposition rates (lowest labor costs) for any application.

[] Imagine a weld shop that does not waste money on useless costly electronic MIG equipment - three part gas mixes and costly metal cored wires. This program shows how the lowest cost MIG equipment and the lowest cost weld gasses and weld wires can meet your all your weld quality and productivity requirements.

WHEN SOMETHING OF GREAT VALUE APPEARS TO BE COMPLEX,
SOMEONE SHOULD MAKE IT SIMPLE:

This MIG package presents the "Clock Method" which I developed over three decades. The MIG Clock Method provides a unique, simple approach to remembering the weld data necessary to attain optimum MIG welds on any steels, stainless, alloy steels and aluminum applications. The program also provides the most comprehensive training approach to attaining optimum productivity and providing welds with minimal defects.

NO WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THIS PROGRAM AND THANKS
TO THE UNIQUE "CLOCK METHOD" SIMPLIFICATION, NO NOTES ARE NECESSARY.

[] This training resource is the only global resource available that provides you with the reasons and logic why you should use the low cost CV MIG equipment and have weld quality concerns when you utilize the more costly Pulsed process, Inverters or Multipurpose welding equipment on all steels and stainless applications > 1/4 (> 6 mm).

[] For those interested in weld consumable cost savings, in contradiction to what your weld sales rep may tell you, this program provides the evidence of why your organization may be wasting money on costly metal cored and flux cored wires and why you should cut back on the gas mixes you use and stop using costly three part gas mixes.

[] The program high lights the root cause of all of your potential weld defects and graphically reveals the instant, practical, cost affective process control resolutions.

The program benefits are many.
[] No more "playing around" with weld controls.
[] Minimize weld rework.
[] Always lowest weld labor costs.
[] 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 useless, costly 3 part gas mixes or metal cored wires.
[] No more guessing at weld costs. In a couple of minutes any weld personnel will be able to tell you the cost of any weld.
[] A weld shop finally unified in it's approach to attaining optimum weld quality and productivity.

WHEN THIS TRAINING IS PROVIDED, ENSURE YOU INCLUDE ALL PERSONNEL INVOLVED WITH WELD DECISIONS, MANAGERS, SUPERVISORS, TECHNICIANS, WELDERS, QA MANAGEMENT AND INSPECTORS.

[3a] The Book.

"Manual MIG Process Controls"

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

[3b] DVD film.

"Manual MIG Process Controls Made Simple".

Produced by Ed Craig. (Run time approx. 60 minutes).

Remember, if a picture is worth a 1000 words this video is worth a million. This DVD is a great introduction to the Clock Method and the simplification of optimum, CV MIG weld parameter selection..

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 3 - 3a - 3b. Total cost $395 plus shipping. (Shipping, $20 USA & Canada or $50 elsewhere)

E-mail: Dear Ed. I am a welding engineer working in the UK. I recently discovered your excellent web site 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: 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 web site. Sincerely. Mike Harris. New Zealand.

ASTEC Industries is America’s leading manufacturer of equipment
for Asphalt Road Building - Aggregate Processing - Pipeline and Utility Trenching.

ASTEC builds is the world's most rugged equipment. In this organization there is no room for weld faults and weld failure. To ensure optimum weld quality and productivity, ASTEC uses Ed's MIG and Flux Cored Best Weld Practices - Process Control Manual Training Resources.

 

THE NEXT PROGRAM IS ON FLUX CORED WELD PROCESS OPTIMIZATION:

From QA forum 2/12/2011:
Ed I have watched the web site "weldreality" for several years and finally purchased one of your courses. If a person does MIG - FCAW for a living, the info you provide is gold. I was amazed at the solid info-no guessing or playing with the weld control info. The weld forums I frequently visit are full of opinions and "try this or we "played around" comments...Ed your process control approach is simple and fool proof, it's solid welding best practices from a proven engineering approach. I have been doing SMAW/GMAW pipe work for many years and never found anyone who could tell me how to set and optimize flux cored / MIG weld parameters- your materials did it in a few hours. I wish I would have found this info years ago..

Thanks Ed.
Regards John.



Item. 4. "Optimum Manual and Automated Flux Cored Pipe - Plate Welds A Unique Weld Best Practices - Process Controls Training Package".

Developed by Ed Craig

Contains items 4 - 4a - 4b.

[4] Training CD: "Pipe & Plate. Flux Cored. Best Weld Practices and Process Controls".

[4a] Book: "Gas Metal Arc and Flux Cored Welding"

[4b] DVD film: "Manual MIG Process Control Made Simple"

Item 4. Package Cost $395 plus shipping. Shipping, $20 USA & Canada or $50 elsewhere.

[4] "Gas Shielded Flux Cored Process Controls".

This Power Point CD is the ultimate Flux Cored weld process
control training program for all manual and automated flux cored applications.

As flux cored is a prime process for pipe welds, also included in this program is MIG Short Circuit, MIG STT and MIG RMD process optimization for the pipe root welds.


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. Professional weld decision makers should have the ability to differentiate the differences between weld defects caused by the procedures, the weld personnel or by the procceses - consumables selected.

IN MANY SHIP YARDS WHERE THERE IS SUPPOSED TO BE FLUX CORED WELD EXPERTISE, YOU WILL FIND FLUX CORED DEFECTS AND WELD REWORK IS MEASURED IN THE MILLION DOLLAR RANGE.

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 their skills and the missing links, knowledge on weld best practices and process controls.

[] Rather than "play around" with weld data, all weld personnel including supervisors should have the ability to instantly change and provide optimum flux cored weld parameters to deal with the common variables found in flux cored applications.

[] The welders should be using the optimum weld techniques that are specific for the flux cored consumables utilized, not using their self taught techniques or the techniques taught by a weld instructor more comfortable with the SMAW (stick) process.

[] You cannot control weld costs unless weld personnel attain maximum weld deposition rates from the weld settings established.

[] It's beneficial for any weld shop if the weld personnel are 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 POWER POINT PROGRAM REQUIRES APPROX. 12 HOURS. AS WITH ALL OF EDS PROGRAMS, NO WELD PROCESS EXPERTISE IS REQUIRED TO PRESENT THE PROGRAM.


This unique program provides everything your workforce could possibly ever need
to know about optimizing manual / automated Flux Cored, (also MIG root) weld quality and productivity on all position pipe, plate, structural and pressure vessel welds.
The flux cored weld wires covered. EX1T-1, EX0T-1, l carbon steels, plus low alloy
and stainless 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 with ceramic backing, welding construction equipment, or welding 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 weld benefits to your self and for the weld shop will be many.

[] A professional weld shop in which weld personnel no longer "play around " with weld controls. The welder sees an issue that effects the weld quality and productivity and instantly provides optimum data and techniques necessary to resolve that issue.

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

[] Weld personnel with the best practice 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. Variables that lead to common flux cored weld defects such as lack of weld fusion, weld cracks, porosity, worm tracks, slag inclusions and spatter.

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

[] For the weld position used each flux core wire size has has two 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 multi pass 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 weld consumable data that you will never get from a salesman.

The CD presents the training program in a simple unique manner, in which without taking notes, 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 Ed;s recommended 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 focused on weld costs, you can be sure these weld recommendations ensure optimum weld deposition rates are always attained, dramatically improving your daily weld production



OPTIMUM CODE QUALITY WELDS NEED OPTIMUM WELD PROCEDURES WHICH
NEED OPTIMUM WELD DATA AND PROCESS INSTRUCTIONS:

Welding ships, trains, pipe lines, oil platforms, refineries, construction projects
heavy equipment, bridges or cranes, there is no better weld data provided than
the data in this program.

THIS PROGRAM DRAMATICALLY REDUCES WELD TRAINING TIME AND 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 program and then provide
three days hands on. That person should be able to produce flux cored welds that
will meet any code requirement for any position welds.

YOU CANNOT CREATE AN EFFECTIVE WELD TEAM WITHOUT A UNIFORM APPROACH TO THE WELDS PRODUCED. YOU WILL NOT PRODUCE OPTIMUM, CONSISTENT QUALITY WELDS AT THE LOWEST COSTS, WITHOUT THE IMPLIMENTATION OF BEST WELD PRACTICES AND WELD PROCESS CONTROLS.

Ed provided flux cored best weld practices and process control training
for the weld personnel at Aker Kavverner Ship yard Philadelphia.

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

Note: For those that think they already have trained employees, try the following weld test. If you are a welder ready to take a flux cored weld test, or an engineer, supervisor, technician or manager who wants to improve your career prospects, it's logical that you should fully understand the process you intend to manage and control.

 

Interested in your level of Flux Cored Weld
Process Control expertise?
Try Ed's Flux Core Welding test

[4a] The Book:

"MIG and Flux Cored Weld Parameter Selection made Simple"

Written by Ed Craig. (156 pages).

For information on this book click here

[4b] 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 consumables used.

Item.4 - 4a - 4b. Total Costs $395 plus shipping. ( Shipping $20 USA & Canada or $50 elsewhere)

Weld Train Resource - Testimonials:

E-Mail. 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 weld process control training resources.

Regards. I C Ormrod. Australia.

E-Mail. 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. 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. Good day Ed. I found your Flux Cored Welding book an excellent weld process control training resource. Chris Stask. Weld Instructor. Camosun College.Vancouver Island BC.

E-Mail. Dear Ed. Your training resources and web site 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 5."Proceso de Soldadura MIG Manual"

"MIG Made Simple in Spanish".

Contains items 5 - 5a.

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

[5a] The DVD FILM. English.

"Manual MIG Process Controls Made Simple".


Produced in English 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 - 5A cost $195 plus shipping. (Shipping $20 USA & Canada or $50 elsewhere)

 

 

Item 6. The Self Teaching Book. English.


"MIG Made Simple in English"

Contains items 6 - 6a.

Written by Ed Craig. (170 pages).

This is a self teaching package is focused 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.

[6a] 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.

Items 6 - 6a cost $195 plus shipping. (Shipping $20 USA & Canada or $50 elsewhere)

For further information on these materials contact Ed Craig at ecraig@weldreality.com.
Phone 828 337 2695

 

REMEMBER WELD PROCESS TRAINING IS THE MOST IMPORTANT SOLUTION TO
REDUCING COSTLY WELD REWORK AND IT'S EXTREMELY BENEFICIAL
IN A TIME OF MANUAL MIG / FLUX CORED WELDER SHORTAGES: