The world's largest web site on weld process controls. www.weldreality.com

 

 

Would a weld professional
have to Ask Lincoln How?


Ed is training his grandson
so he wont have to
Ask Lincoln How!


Best Weld Practices and Weld Process Controls cannot
be implemented without Process Control education or training.

 



Ed has developed the world's most effective MIG /
Flux Cored, Manual / Robot Weld Process Control
Training and Educational Resources.

 

The following are the books, video, DVD and CDs developed by Ed Craig.


[A] Book. A Management and Engineers Guide to MIG

[B] Book. Gas Metal Arc and Flux Cored Welding.

[C] Book. Manual and Robot Gas Metal Arc Welding.

[D] Video / DVD. Manual MIG Process Control Made Simple.

[E] CD Power Point Training Program. Robot Process Controls for all Steel Gage Applications, < 4 mm using short circuit or pulsed transfer.

[F] CD Power Point Training Program. Robot Process Control for all Steel Applications > 2 mm using Spray and Pulsed.

[G] CD Power Point Training Program. Manual MIG Best Weld Practices and Process Controls.

[H] CD Power Point Training Program. Gas Shielded flux cored Pipe and Plate welds. Best Weld Practices and Process Controls.


Scroll down for information on the above products.



[1] Book:
"A Management, & Engineer's
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.

Cost $160. Order Here

 

Hi Ed;

I have been through your book several times now (Management and Engineers Guide…) Coming from a pressure vessel background I can share 100 stories with you as to why various welders or management decision makers avoided the MIG or flux-core process. All based on myth or history. I am currently a welding engineer in the automotive industry. Your book has helped educate and inspire me in many ways. I feel very fortunate to now have practical process experience and theoretical process knowledge in MIG, TIG and Stick. The interesting element in my personal development and evolution is this,”The more I learn, the more I find there is to learn.” That is what makes it all so exciting. 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. Ont: Canada.
Hydroform Solutions On. Canada.


Ed.

I have just read your Chrysler Neon article regarding the cross members and self shielded flux cored wire issues. I fully endorse your views and comments. Its a shame that many "weld engineers" in the automotive industry lack the actual knowledge and skills to fulfill this critical role. I myself am a welding engineer for a tier one supplier to the UK auto industry and see this too often. As an engineer and also time served boilermaker, I feel that there is a tremendous lack of MIG weld process knowledge and experience with the welding and engineering personnel in the auto industry. I must also thank you for your books 'A Management & Engineering Guide to MIG and the great MIG Training' materials. We as a company refer to them regularly. Cheers

PL - England.

Dear Ed,

I am very interested your guide book, “A Management & Engineers Guide to MIG Welding Quality Costs Training” We are are an auto / truck frame manufacturer located in Thailand. My friend who works for Dana - Structural Solution Group in the United States suggested we get this book.

Regards, Kanit. Product Engineer. Thailand.


Dear Ed. Love the site, its a great weld resource and a comforting reassurance that I really wasn't the problem. I have been welding for 17 years and had different gases thrown in my face by salesmen along with extensive weld advice and parameters that just didn't seem to make sense, not to mention all the "learning curves" that I seemed unable to attain. With your Management / Engineers book, I finally have found the process control book that I need.

Regards. Kevin Gough.USA.

 


"Some times you don't pick the book, it will pick you." Rubin Carter.





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

Ed presents a unique simple approach to manual weld parameter selection for both
MIG and the Flux Cored process.

Written by Ed Craig.


Cost $90. Order Here


Good day Ed. I found your Gas Metal Arc and Flux Cored Welding book an excellent weld process control resource.

Chris Stask
Welding Instructor
Camosun College
Vancouver Island BC

 

From: "Dave Helliwell" <djhelliweld@hotmail.com

Hi Ed. I Just wanted to say thanks for the welding books, the weld process control advice
in them is priceless. Thanks a Million. David.






[3] Book: " Manual / Robot Gas Metal Arc Welding"


Written by Ed Craig.

This manual and Robot MIG weld Process Control Training book is the key tool for MIG weld quality / productivity optimization.

Ed's unique, process control Clock Method provides a simple training approach to the selection of optimum MIG parameters for any robot carbon steels, alloy steels and stainless applications. Available in both English and Spanish.



OPTIMIZE THAT ROBOT MIG WELD EFFICIENCY BY MINIMIZING ROBOT ISSUES: Address contact tip, wire burn backs, weld start issues, crater and undercut problems, weld spatter, inconsistent welds, burn through and lack of fusion.

Be aware of weld cost, weld deposition and weld speed potential for any applications . Once you read this 160 page book and answer the 160 questions there is no reason for playing around with the MIG weld controls.
This book also available in Spanish,its ideal for anyone who is making manual and robot weld decisions.

I believe this is the world's most effective Self Teaching manual and Robot MIG/MAG Weld Process Control Training book. Try it with the following video and if you want to train weld personnel with the following CD "Robot Process Control Training Program".

Please note: Copies of this book have been made and passed around without Ed's permission.
I will take legal action against any company that infringes on copy right laws.


Cost $90. Order Here



E-mail. From Jose Ignacio Moreno. Spain.

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

Thank you JM.


E-mail From: Tom Plummer:


Good afternoon Ed.

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

Tenneco .USA.
Aug 2007:


E-mail July 06:
From Dana Corporation Employee:


Jan 2007: Ed I wanted to send update about that E-Town plant that you visited a few years ago: As you know on your first visit to this plant, our robot lines were producing less than 40 truck frames per-hour and the majority required extensive weld rework. Thanks to your weld process control / best weld practices 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.

Many thanks GR!
A Grateful Employee
Dana Corporation.


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


From Ed: Scroll down for this Robot Process Control Train Program, or call Ed for info at 828 658 3574



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

 


[4]Video / DVD. "Manual MIG Process Control Made Simple".

Produced by Ed Craig.

Available also in DVD format
.

No more playing around with the MIG equipment weld controls. Ed developed over three decades The "MIG Clock Method" . This is the world's most unique and simple approach to setting optimum MIG, short circuit, and spray data for any steel or stainless applications. Just present this one hour video to your employees and bring a uniform approach to attaining optimum weld quality and productivity for your shop.



Cost $125. It's $90 when ordered with
any other product. Order Here.



E-mail From Marcus di Sabella

Ed, I just received your process control materials and within five minutes n 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!

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

 


Best MIG Weld Practices and MIG Weld Process
Controls can be implemented with
the following Training CDs.

 





This is it. Four of the world's most effective robot / manual MIG and flux cored
weld process control training programs.

 


[5]
Robot Process Controls for all Steel Gage Applications < 4 mm using Short Circuit or
Pulsed Transfer.


A Power Point Training Program available on a CD.


Produced by Ed Craig
. Price $189. Click here for information

Order Here.


Ed took over 2500 hours to develop t
hese Two unique, Robot Process Control Power Point Training Programs.


CD's E-F are applicable to all robot / automated carbon steel / stainless welds.
These valuable CD resources, provide more highly effective robot weld process control data than all the combined global resources.




[6]
Robot Process Controls for all Steel Gage Applications > 4 mm using Spray Transfer or
Pulsed Transfer.

A Power Point Training Program available on a CD.


Produced by Ed Craig
.
Price $189. Click here for information


Order Here.


If you need more data on any of the programs or resources call Ed at North Carolina 828 658 3574 - 770 330 9933, or E-mail. Ecraig@weldreality.com.

Consider items C and D (above) with CDs E-F:






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

E-mail July 06: To Ed Craig:

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 the 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!

RG: A Grateful Employee
Dana Corporation.


For questions call Ed at 828 658 3574 or e-mail ecraig@weweldreality.com.

Use item D above with this program for your complete training package.

 

I BELIEVE THIS MIG WELD TEST EXPLAINS THE IMPORTANCE OF WELD PROCESS EXPERTISE THAT'S NECESSARY FOR THE ESTABLISHMENT OF WELD PROCESS CONTROLS.

 

[7] A UNIQUE MANUAL MIG TRAINING PROGRAM:

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


The world's most effective, manual MIG training program for your weld personnel. This unique Power Point Program is a available on a CD.

Produced by Ed Craig. Price $189. For information click here.

Order.

 

 


[H] "Gas Shielded Flux Cored" Pipe and Plate Welds: Best Weld Practices and Weld Process Controls"

Produced by Ed Craig. Available on a CD:

Flux Cored Program. Cost $189. Order Here.


This CD training program is the most comprehensive weld process control resource ever developed for the Gas Shielded Flux Cored weld process. Developed for all position, Carbon Steels / Low Alloy Steels / Stainless Pipe and Plate Welds. Also included is a MIG short circuit / STT / RMD section on welding pipe open roots.

An incredible flux cored Training Resource.


Worried about your flux cored, vee grooves, plate, pipe, weld rework, weld repair costs, weld productivity and product liability?

Do you weld all position, plate, pipe, pressure vessels, oil storage tanks, construction, heavy equipment, large fabrications, bridges, structural steels, ships? Do you weld on vee groove applications with open roots, or roots with steel or ceramic backing?

This program presents unique, cost affective, solutions to over sized weld gaps.


You will worry less about lack of weld fusion, excess porosity, weld cracks, or slag inclusions as this program teaches the weld personnel how to avoid the weld defects before they occur. This unique flux cored weld program provides the Best Weld Practice and Process Control requirement necessary for any welding shop that wants to be at the top of what it does.

Flux Cored. The CD Power Point Program Contents.
[] Everything you need to know about all position flux cored wires.
[] Why pulsed equipment or Inverters may impair those flux cored welds and which weld equipment works best with flux cored wires.
[] Why stick weld techniques cause flux cored weld issues.
[] Correct flux cored weld techniques for all position vee groove welds on open roots and ceramic / steel backing.
[] When to use fore hand and back hand.
[] How to prevent weld defects, porosity, worm tracks, lack of weld fusion, cold hydrogen cracks and hot plate and hot weld crack's.
[] Why you should use E701-1 versus E71T-1 wires.
[] When to use MIG versus flux core.
[] The correct flux cored wire diameter for optimum weld fusion and weld deposition rates.
[] The differences between CO2 and Argon CO2 flux cored welds.
[] The correct utilization of wire feeders and guns with a great trouble shooting section.
[] Correct weld edge and plate preparation for flux cored vee groove welds.
[] How wire stick out variations can work for or against the weld.
[] Ed's unique Weld Clock Method". This process control method simplifies the required flux cored weld parameter selection for all steel and stainless flux cored plate and pipe welds. No notes required by the weld personnel as this data stays in their head.
[] Ed's unique clock method also focuses on attaining maximum weld deposition rates, and also makes it easy to figure out flux cored weld costs.
[] How the flux cored weld surface will reveal the weld internal quality.
[] With pipe and plate vee welds, use Ed's special instruction to minimize the weld defects that typically occur in the common vee groove locations.
[] Cap welds, root welds and fill passes all require unique techniques and weld settings for optimum weld quality.
[] MIG welding the pipe roots, the right way.
[] Ed's 12 steps to flux cored welds. These welds will not require rework.



It took Ed over 500 hours to develop this very unique training program.


If you want a fast track training program this is it. If your weld personnel apply the unique flux cored Weld Process Controls, Best Weld Practices, Skills and Techniques provided in this program, you will see dramatic improvements in your manual flux cored weld quality and productivity.

Flux Cored Program Cost $189 Order Here.


HOW WELL DO YOU THINK YOU KNOW
THE FLUX CORED PROCESS . WHY NOT TAKE TEST?


Bring Process Uniformity and Control to your weld shop.
Best FCAW Weld Practices and Weld Process Controls
can be implemented with the following
Process Control Training Resources.

More data on the world's most unique
Flux Cored Process Control Training Program. Click

 


E-mail Feb 2007

Ed. I have read book about flux cored weld parameters and reviewed the CD flux cored training power point slides many times. The methods in which you address the root cause of the common flux cored weld issues is unique and makes complete sense. Your program simplifies the requirements for all position plate and pipe welds, and made those difficult ceramic backed vee groove applications one less thing to worry about. I have learned many things that give me a better understanding of how to quickly correct the weld issues and set the weld equipment for the many variables that occur. By the way you are correct most of these welders I work with know little about how to set machine correctly. Because of their improper parameters and techniques they daily create lack of fusion, porosity and slag issues. What's ironic is after they repair the welds, they then create more of the same weld problems. Thanks again for the flux cored book and CD.

Gary
253 405 6414

 


This group is part of the 300 ship yard welders who went
through Ed's flux cored process training program.

Jan 2007: Ed and Tom (blue sweaters) provided flux cored Weld Process Control
Training, for Aker. This company builds oil tankers.
Location: Excel Weld Training Center, the Philadelphia Naval Ship Yard.


 


 

In the nineteen nineties, Ed was asked to establish Best flux cored and MIG Weld Practices and Process Controls for the SMAW pipe line welders employed by Imperial Oil, Alberta.

The one day, flux cored process control training program provided dramatically improved the pipe weld quality / productivity. Imperial engineers reported that this eight hour training program produced an annual cost savings of more than one million dollars for this one pipe crew.

 

 

Steve Bleile
wallmountain@imbris.net


Ed: Just found your site and I am slowly going through it. I hope you enjoy doing this, because it sure is an asset to the industry. I'm a retired pipe welder, and now teach welding. I have some experience welding with MIG and gas shielded flux cored wires, but I'm weak in the welding processes and parameters. (I'm ordering your book tomorrow.) Would it be all right if I asked you some questions (after I read the book) so I can enlighten my trainees. When I have had weld technical questions I have tried both Miller and Lincoln techs, but either get answers that make no sense or no answers. Regardless, great job on this site. Steve.

 

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.

Regards; Fraser Rock. Weld Engineer / Weld Analyst.

Hydroform Solutions On. Canada. L6S 6E5

 

Dear Ed, Your website is very useful to me . I admire you for your knowledge in welding. You are really are a great welding engineer. If you visit Saudi Arabia please contact me. I am eager to meet you.

With great respect and regards,

B. Muralidaran.
Saudi Arabia.



Hi Ed, The books arrived on Friday and I can see from the couple of hours reading I've done so far that they're full of valuable knowledge. Thanks for books and website.

Best regards
Mike Harris
New Zealand.



Dear Ed,
I am a welder living and working in Australia. I found your web site and am very interested in your book "Manual "Gas Metal Arc & Flux Cored Welding Parameters". 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 properly. 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 training resources.

Yours sincerely
I C Ormrod
Australia

 

Letter. Feb. 2004. 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 books 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




THERE IS A SIMPLE SOLUTION TO MANUAL
MIG / FLUX CORED WELDER SHORTAGES:

PLUS A SOLUTION TO OPTIMIZE MANUAL AND ROBOT
MIG WELDING PRODUCTIVITY / QUALITY:




PROVIDE PROCESS CONTROL TRAINING AND DRAMATICALLY REDUCE WELDER TRAINING TIME: A common problem for welding manufactures, is the shortage of skilled MIG and flux cored welders. Yet with the correct type of process control training provided in Ed's training resources, in combination with the conventional skills training , it typically takes approx. five to eight days 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.


ROBOT WELD OPTIMIZATION ONLY COMES AFTER MIG WELDING PROCESS CONTROL TRAINING: The aggressive growth in arc welding robots is also aggravating the weld employment issues. While managers rush to purchase more robots, few robots have achieved their weld production / quality potential and few global manufacturers or weld shops provide the necessary process control training for optimized robot weld quality and productivity.
Using Ed's Robot weld process control training resources, with a few a few hours of the training program, tremendous improvements can occur with your robot weld quality and productivity.

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 and the implementation of Best Weld Practices and highly effective Weld Process Controls.


Remember weld job security comes
with weld process Knowledge:



COULD YOUR WELD PERSONNEL ANSWER
MIG WELD QUESTIONS LIKE THESE?

Question. You will be robot welding 10 to 12 gage carbon steel or stainless parts using short circuit transfer. The welds a 3/16 (5mm) fillet. The weld wire 0.035 (1mm). The weld parameters are too cold, you want to attain better weld fusion and speed up the robot process. You decided to set the "low end" of MIG Spray Transfer weld parameters for the 3/16, 4.8 mm fillet weld. What is the optimum wire feed and voltage setting and deposition rate for the start point of spray transfer with the 035 wire? What would you then set the robot weld travel rate at?


Question. You are pulsed welding and there is weld spatter on the part. You adjust the "trim voltage" (arc length), nothing happens. What other pulsed parameter change will rectify the situation.

Want more questions? try Ed's Weld Process Control Test.


If you have to look at a book to resolve weld questions you have not learnt Ed's EASY CLOCK METHOD for weld process controls.



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 J. Winter. Ontario. Canada.

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 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.
Canada.

For those of you who have Spanish speaking robot MIG personnel.
While working in Vigo, Spain on Citroen robot welded 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. Alex translated my robot weld process control book into Spanish. If you want the robot / manual process control training book in Spanish, please order by e-mail, ecraig@weldreality.com or call my wife Janet, at 828 658 3574.


E-Mail:

Dear Ed
Thank you for your kind response and fast shipment of the process control books and video. 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.

 


It helps if you have a sense of humor,
when you are in the welding buisness

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



 

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:



 

Ed Resolves Numerous Weld Problems with a Phone Call.

If you are looking for 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.

 

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

 


Contact Ed Craig, he is the one in the middle. Asheville. North Carolina. USA. Phone 828 658 3574, day or evening. (Eastern Time)



E-mail Ed at ecraig@weldreality.com.

 


copyright © Ed Craig, All Rights Reserved. Web hosting provided by Sage Island.

Email Ed Craig at ecraig@weldreality.com

 
 
 
 
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