Weld Practices and Weld Process Controls cannot
be implemented without Process
has developed the world's most effective MIG /
Flux Cored, Manual / Robot
Weld Process Control
Training and Educational Resources.
"A Management, Supervisors & Engineer's Guide to
MIG Weld Quality, Productivity and Costs"
comprehensive book ever written on the total process requirements necessary to
establish MIG Weld Best Practices and Weld Process Controls.
by Ed Craig.
$160. Order Here
Book: "Gas Metal Arc
and Flux Cored Welding"
presents a unique simple approach to manual weld parameter selection for both
MIG and the Flux Cored process.
by Ed Craig.
$80. Order Here
From: "Dave Helliwell" <email@example.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.
Book: "Manual and
Robot Gas Metal Arc Welding"
optimum robot or manual MIG weld parameters? The unique Clock Method presented
is a simple approach to the selection of optimum MIG parameters for any carbon
steels or stainless applications. Once you read this 160 page book there is no
reason for playing around with the MIG weld controls. This has to be
the world's most effective Self Teaching MIG Weld Process Control Training book.
Try it with the following video.
by Ed Craig.
$80. Order Here
those of you that wonder about the level your MIG weld process
why not test your self
Video. "MIG Process
Control Made Simple".
also in DVD format.
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.
by Ed Craig.
$125. It's $85 when ordered with
any other product.
Process Uniformity and Control to your weld shop.
MIG Weld Practices and Weld Process Controls
can be implemented with the following
MIG Process Control Training CDs.
A Unique Power Point Training Program on a CD.
Best Weld Practices and
Weld Process Controls"
by Ed Craig.
$275. Order Here.
CANNOT PROVIDE MIG BEST WELD PRACTICES OR IMPLEMENT MIG WELD PROCESS CONTROLS
IN ANY WELD SHOP WITHOUT FIRST PROVIDING ALL WELD PERSONNEL WITH THE RELEVANT
"MIG PROCESS CONTROL TRAINING".
note: The skill levels and experience of your weld work force has nothing to do
with Process Control Training.
took over 2000 hours to develop this MIG training program suited for all carbon
steels, alloy steels and stainless applications.
The Power Point CD program
enables weld shop process uniformity and provides the opportunity for consistent
weld quality along with a dramatic potential reduction in weld costs.
1: Weld Best Practices
Look around your weld shop and count the many different types of MIG power sources
your company has purchased. Should you purchase an Inverter, a Pulsed power source
or regular CV equipment. One MIG power source for the shop, improves operator
familiarity, simplifies weld process training, reduces weld equipment cost and
reduces maintenance concerns. This program cuts through the weld equipment salesmanship
and provides the optimum MIG equipment for your organization.
program shows you how to save up to 50% on your weld equipment purchases.
Reduce the weld consumables and gas mixes used in the shop.
This program shows you how one weld wire and one gas mix
can provide the highest possible weld quality and productivity.
2: Weld Process Controls.
For more than five decades weld personnel have played around with MIG weld controls.
This program provides a unique, simple approach to weld mode and parameter selection
for any carbon steel or stainless applications.
If you have looking for a simple approach to weld cost
analysis and weld cost control , this is it.
carbon steels or stainless sheet metals to any steel thickness, this training
provides many cost effective benefits:
PROCESS OPTIMIZATION: Welders will fully understand the optimum weld parameter
ranges of short circuit, spray and the pulsed process and will be aware of when
to switch from one mode to another.
 WELD QUALITY:
Welders will be aware of the potential weld issues before they weld and use their
process expertise to ensure consistent, optimum quality and minimum weld rework.
OPTIMUM PRODUCTIVITY: All weld personnel will know on any application how to attain
maximum weld deposition rates that will ensure optimum daily weld productivity.
UNIFORM CORRECT TECHNIQUES: All weld personnel will use a uniform approach to
MIG weld process optimization
and instead of using inappropriate stick weld techniques, all will l use the most
effective MIG weld techniques necessary to minimize the opportunity for weld rework,
present this four hour program requires no weld process
control expertise. You simply present the slides to
your weld personnel. As welding is an important function in your organization
ENSURE include all weld decision makers, welders, technicians, supervisors, engineers,
QA personnel and managers. In four hours you have the keys necessary
for the implementation of cost effective manual MIG Best Weld Practices and MIG
Weld Process Controls.
For questions call Ed at 828 658
3574 or e-mail firstname.lastname@example.org.
item D above for your complete training program.
$275. Order Here.
BELIEVE THIS TEST EXPLAINS THE IMPORTANCE OF WELD PROCESS EXPERTISE FOR THE ESTABLISHMENT
OF WELD PROCESS CONTROLS.
A Power Point Training Program on a CD.
"Seven Steps to
Robot MIG Weld Best
and Process Controls:
by Ed Craig.
$375. Order Here
took over 2500 hours to develop this unique
CD Power Point Training Program.
this comprehensive CD in your computer and you have all the data necessary to
address your plant's robot MIG weld quality / productivity issues on any carbon
steels, alloy steels or stainless robot applications.
Ed simplifies the
requirements for robot MIG weld process optimization and provides unique weld
process solutions to those numerous robot welding issues.
Note: The weld
decision maker who presents this Power Point presentation need minimal weld process
robot Down Time and Robot Efficiency Potential (REP) data
that's presented in this program is extremely beneficial, as the global REP average
for robot MIG welding is only 60%.
program provides unique process solutions that show how to consistently attain
over 98% Robot Efficiency Potential
and less than 2% Robot Weld Rework.
REWORK: In a few hours the training instantly provides the
Robots and Weld Start Issues.
Robots and Weld Burn Through.
 Robots and Wire Burn backs.
 Robots and
 Robots and Weld Crater Issues.
 Robots and Weld Arc Start
Robots and Inconsistent Welds.
 Robots and Poor Weld Profiles.
and Excess spatter.
 Robots and Crater issues.
 Robots and Lack of
 Robots, Porosity and Weld Cracks.
VARIABLES EFFECT ROBOT WELD EFFICIENCY POTENTIAL: Being
aware of the factors that influence your real world weld robot weld efficiency
, and providing the solutions, can drive down your robot weld production costs
typically by 25 to 50%. This program provides the
7 steps necessary for maximum Robot Weld Efficiency Potential. (REP).
Robots and Weld Cost: Weld costs goes way beyond the price of the welding
consumables. Ed presents a very simple practical approach any one can apply for
both Weld Cost Analysis and Weld Cost Control.
Robots and Cycle Times:
The program shows you how to optimize robot cycle times. Once applied, typically
you can anticipate a 20 to 50% increase in your daily
robot weld productivity.
 Robots and Weld Rework:
The annual global robot MIG weld rework costs easily surpasses 1 billion
dollars each year. This program provides the information necessary for any company
to attain a daily robot weld rework
of < 2%.
Designers and Lack of Weld Process Awareness: If
designers receive this training they could actually design robot parts and fixtures
that enhance the opportunity for increased robot weld quality
Robots and Understanding the Welding Process:
Many of the global individuals who run robots
are simply "operating a process", rather than in control of that process.
You cannot implement Best Weld Practices or establish Weld Process Controls without
the comprehensive Robot Weld Process Control data provided in this unique, yet
simple training program.
MIG Equipment: For every 10 power sources your company
purchased for those robot cells, this program shows you how you could have saved
up to $50,000.00. The training also makes you aware
of why Inverters and Pulsed MIG equipment can enhance weld quality on some applications
and have dramatic negative weld quality impact on other applications.
Robots and Weld Consumable Selection: The majority of automotive plants
use the wrong size weld wires which dramatically impact the daily weld quality
and productivity. Get the consumable facts for the different wire diameters and
their suitability for the specific weld transfer modes, deposition rate potential
(robot travel rates) and applications.
Robots and Weld Process Calibration:
Few global robots have received correct robot / power source calibration. From
a weld manufacturing quality and liability potential, I hope you understand the
importance of this subject. Ed provides the real world contractual calibration
requirements that should be applied when you order those robots.
Robots. Deposition Rates and High Speed Welds: Ed
has patents on items that enhance single wire MIG weld production. He has extensive
expertise in maximizing robot weld productivity. While some companies look to
invest over $100,000.00 on Twin wire weld equipment to attain typical weld deposition
, rates of approx. 20 lb/hr, Ed shows you how to attain up to 18 lb/hr using a
single MIG wire.
IMPORTANT DO YOU BELIEVE THESE QUESTIONS ARE TO YOUR ORGANIZATION?
What is the wire feed start point for spray transfer with that 0.045, (1.2mm)
or that 0.035 (1 mm) E70S-6 carbon steel wire? What thickness do you use this
wire feed setting on?
Increasing robot weld speed. Do you increase or decrease voltage. Why?
is it a waste of money to use a three part gas mix for steel and stainless?
Why be concerned with weld fusion with that Inverter power source on that 3/8
(10 mm) steel or stainless application?
 What is the normal weld deposition
rate for a 1/4 (6 mm) fillet weld?
 At what parameters do an 0.045 (1.2
mm) steel wire change from short circuit to globular?
 How can you attain
18 lb/hr weld deposition rate with the MIG process and what application is this
 Welding carbon steels or stainless, when should you switch from
short circuit, pulsed or spray?
If that pulsed weld was inconsistent, or you needed superior weld fusion, could
you immediately provided the optimum spray transfer wire feed, voltage and travel
speed and produce a spray weld that provides superior weld fusion, a weld that
provides the same cycle time or even better weld production?
 If that
spray weld was causing distortion, could you provide a pulsed weld that produces
lower weld energy without lowering the weld speeds?
If that short circuit weld was not optimum, what pulsed current or wire feed setting
would you utilize so you don't burn through the part and you maintain or improve
you purchase this CD, your weld personnel will no longer "play around"
with weld controls and your organization will have the tools necessary to provide
a consistent, uniform approach to recognizing the
root cause of your daily weld issues.
When you provide the Seven
Steps necessary for robot weld optimization, you are ready to
Robot Best Weld Practices and Robot Weld Process Controls.
items C and D (above) with this training CD:
$375. Order Here
program is applicable to all robot and "manual" carbon steel / stainless
welds, produced by either MIG or Pulsed MIG. 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.
July 06: To
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 weld 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
From PL England.
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
WELL DO YOU THINK YOU KNOW
THE FLUX CORED PROCESS . WHY NOT TAKE TEST?
Process Uniformity and Control to your weld shop.
FCAW Weld Practices and Weld Process Controls
can be implemented with the
Process Control Training Resources.
A Unique Flux Cored Power Point Training Program
on a CD.
"Gas Shielded Flux Cored" Pipe and Plate Welds:
Best Weld Practices and Weld Process Controls"
by Ed Craig.
Cost $275 Order Here.
CD training program is the most comprehensive weld process control resource ever
developed for the Gas Shielded Flux Cored weld process. Developed
for all positions, Carbon Steels / Low Alloy Steels / Stainless Pipe and Plate
included is a short circuit / STT / RMD MIG section on welding pipe open roots.
incredible Weld Process Control Training Resource.
about your vee grooves, plate, pipe, flux cored weld rework, weld repair costs,
weld productivity and product liability?
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
This program updated monthly presents unique, cost affective,
solutions to over sized weld gaps.
The Clock Method developed by Ed shows
the four settings that can produce optimum flux cored weld quality / productivity
on all steel applications. Highly skilled welders will stop playing with their
weld controls and inexperienced welders will within a few days have the ability
to weld any flux cored application.
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.
took over 500 hours to develop this very unique training program.
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.
data on the world's most unique
Flux Cored Process Control Training Program.
I have read book about FCAW weld parameters and reviewed the CD flux cored training
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.
253 405 6414
$275 Order Here.
group is part of the 300 ship yard welders who went
through Ed's flux cored
process training program.
2007: Ed and Tom (blue sweaters) provided Weld Process Control
Aker. This company builds oil tankers.
Excel Weld Training Center, the Philadelphia Naval Ship Yard.
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.
day 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.