Back to Previous Page


The information on this site is critical of the too frequent, inappropriate, sales practices that often bring disrespect and confusion to the welding industry.

If you have been in this industry for decades, you will know that when it comes to "MIG" the worlds most important welding process, that advances in welding equipment and consumable weld technology are too frequently a figment of a weld equipment, marketing managers imagination.

In a time when weld automation is becoming more important than manual welding, many MIG customers are taking all the manual weld shop myths and diseases of the last five decades and placing them in the robot welding cells. Too add to the extensive weld contamination, some of the major weld equipment and consumable manufactures who in reality bear a great responsibility for the majority of weld shop myths are now with the aid of electronics and marketing propaganda adding more useless bell and whistles with exaggerated product claims to their welding products. The bottom line, look forward to another decade of weld shop chaos and confusion.




Its only fitting that my last weld consulting job in the year 2000, would be working with "pulsed" MIG equipment at a GM plant in Ohio.

The job was simple. A new multi-million dollar production line set up to automatically weld torque converters. The problems generated, [a] A 2% leak rate from the multi MIG welds, and [b] excess weld heat from the multi-torch operation caused production assembly issues. Four days into my visit the 2% reject figure was reduced to "0%" the weld heat problems was eliminated, and as a bonus I gave them 15% more production.

What I found interesting about the costly, high volume installation, was the two weld production lines used six Lincoln Power Wave power sources. The lines were not yet in the production mode, yet the plant engineers informed me that four of the six pulsed power sources had already been replaced.

As a matter of weld interest, the pulsed mode was found not ideal for the application, (numerous, costly pulsed power sources are purchased in North America and the pulsed modes are never used). The bottom line the weld application was welded with spray transfer which was found to be more stable than the pulsed mode.

If the lower cost, traditional, more durable Lincoln CV 400 power sources had been purchased, I know several GM engineers that today would have more respect for the red welding equipment.


For the last five decades the gas metal arc weld process, (commonly called MIG) has been the worlds most important welding process. This process along with flux cored wires now account for more than 80% of the welds produced daily in manufacturing shops. The traditional MIG equipment typically requires no more than two controls.

It's a sad weld reality that most of the universities and colleges in North America that offer welding degrees, placed little emphasis on teaching the potential weld engineers and technicians the ability to establish effective MIG or flux cored weld process controls.

At many universities that teach welding, too much time is often spent on classroom text book weld processes such as laser or electron-beam. These interesting, black board, high tech processes account for a fraction of one percent of the daily welds produced in industrial countries.

If more practical and classroom time was spent on MIG, flux cored and resistance weld process controls, the automotive and weld manufacturing industry would generate hundreds of millions of dollars daily through improved welding productivity and quality. Unfortunately this is not likely to happen in the short term, the reasons; few universities or colleges hire engineering department heads, with the practical technical ability to recognize what the manufacturing industry needs.

Most universities or colleges do not recognize the technical process expertise required by professors and teachers to implement weld process controls. The bottom line the emphasis in teaching weld engineers will likely stay on traditional classroom topics such as metallurgy or NDT combined with instruction on, how to produce an electron beam weld.

©2001 Ed Craig, All Rights Reserved. Site Designed and hosted by Orotech.

Email Ed Craig at
If urgent call Ed on his cell phone -

|Steels & Weld Consumables| |Weld Training| |Weld Product Questions| |Metric Weld Conversions| |MIG & Flux Core Data| |Ed's Training Materials| |Weld Consulting| |Who Is Ed Craig?| |Contact Ed Craig|