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Welding Books

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

Gas Metal Arc Welding Book
Manual and Robotic (MIG) Gas Metal Arc Welding Book

MIG and Flux Core Welding Book
Flux Cored and MIG weld process controls

Manual MIG Welding Book
Manual MIG Welding Process Control

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

Welding CD's

Robot Welding CD
Robot MIG welding. Best Weld Practices and Process Controls

MIG Welding CD
Manual MIG Welding. Best Weld Practices and Process Controls

Flux Core Welding CD
Flux Cored Best Weld Practices and Process Controls

MIG Welding Process Controls
DVD Film "MIG Process Controls Made Simple"

Order these MIG Welding or Flux Cored Training Materials Now

ED CRAIG. www.weldreality.com.

The world's largest website on MIG - Flux Cored - TIG Welding

Motorman Robots

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


Motorman Robot Concerns?

The following is an E mail sent to me March 2001, I have deleted the name of the person and companies name. Anyone else have beyond the norm robot issues, send me an email.

Ed, we are on our 4th generation of Motoman robots, and I didn't think they could get any worse, but I was wrong. I simply would not recommend the new UP/XRC robots to anyone. We have had nothing but problems with them. Motoman has a real problem with the encoders in their motors, and we have replaced everyone at least once. In addition, I have a servo pack or motor go out on an average of once per week. They are also having wire harness problems with the insulation prematurely wearing out. I have had to replace four so far, and we have only been running since August. We have also had to replace 13 boards in the main processor. They are saying that the Panasonic power sources are creating noise in the unit and taking out the boards, but we are not really buying it and neither is Panasonic. What a nightmare.



[1] If you have robot weld rework on more than 2% of your parts.
[2] If you utilize three part gas mixes for carbon steels or thin gage stainless.
[3] If you believe you can produce welds with a Metal Cored wire which you cannot do with a lower cost MIG wire.
[4] If you utilize flux cored wires for welding clean carbon steels <3/8 in the flat and horizontal welding positions.
[5] If you weld carbon steels and you use mixes containing oxygen.
[6] If you purchase your primary weld supplies from more than one supplier.
[7] If the person who has full responsibility for the robots is in the union.
[8] If your company allows operators or anyone other than the programmer to make welding parameter changes to the robot program.
[9] If your purchasing personnel make decisions on the consumables selected.
[10] If there is no weld parameter data posted on the weld equipment or along side the robot cells.
[11] If your manual welders daily use a whipping action or weave action with their MIG guns.
[12] If your robots have a ROBOT down time per shift of more than 15 minutes.
[13] If you use pulsed MIG and don't know how to provide optimum pulsed parameter adjustments, or you are not aware how your pulsed weld deposition rates compare against the lower cost spray transfer.



With the recent evolution of this high weld speed, high deposition rate, high weld speed process, many of the negative weld issues that were a part of the process since its inception have been now been eliminated.

Using the conventional MIG process, try and run two MIG wires into the same weld puddle and you would have arc, heat and weld puddle issues.

With the twin wire MIG process the welding equipment utilized and the position of the wires are such that the forces created by the magnetic fields will interact and reduce reactions on the arc plasma. The two wires create a common arc in which part of each arc is directed to the other arc. The bottom line the arc plasma pressures on the resulting weld surface are reduced allowing twice the normal MIG welding deposition rates, this of course allows for much higher welding speeds. Go to MIG equipment to find out more. If a weld shop has issues with the regular, two knob control single MIG wire process, then this shop should give careful consideration to the twin wire process. There are many ways to greatly improve weld speeds without resorting to Twin Arc. I have produced single wire 3/16 fillet welds at 90 in./min. If you want more welding data on theses subjects call 970 988 1169 and attain my "Management Engineers MIG Book".


Everyone in the welding industry should be aware of the extensive confusion that has surrounded the MIG process for decades. The weld reality on educating people on the worlds most widely used welding process, is that regardless of the application each popular MIG electrode wire size used has typically only three optimum short circuit and three spray transfer wire feed settings for all welds made in the flat or horizontal positions. To further simplify the weld parameter requirements each process or mode of weld transfer requires a very narrow weld voltage range.


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