WHO IS ED CRAIG?
2013: Hello, my name is Ed Craig.
I have been involved with MIG and flux cored weld optimization for 50 years. Approx. thirty five years ago, I started to simplify weld process controls - best practices, and develop my MIG, " Weld Clock Method', (WCM).
My WCM simplifies both MIG - Flux Cored Weld Process Controls - Best Weld Practice.
With less than 16 hours, these training or self teaching resources, will irrespective of the participants weld back ground, education or weld experience, provide individuals with the ability, without playing around with their weld controls, to instantly provide optimum
weld data, parameters and weld practices for any MIG - Flux Cored, manual or robot, weld applications.
It's logical that extensive weld cost benefits would be derived from any company that has trained it's employees to consistently attain the highest possible MIG and Flux weld quality and productivity, with the lowest cost MIG weld equipment and consumables, and that's what I did for five decades in over 1000 companies in 13 countries.
2014: Weld advice from individuals that sell weld processes and consumables may often be biased or misleading. Typically the weld advice adds to the weld shop process confusion, and to the weld myths that have been part of this industry for more than five decades..
During the last fifty
manual and robot weld issues on many of the world's most complex weld applications.
I created five international weld patents, from pulsed weld cladding boilers,
to the invention of the
One of my MIG patents was a copper, ceramic, contact tips. These tips enabled much longer MIG wire stick outs, which doubled the weld deposition rates and greatly increased weld speeds on many MIG robot applications.
a few years in weld development and research with Canada's Nuclear Research facility. I worked on many Oil, Power and weld research projects for the Canadian Weld Institute. I was the weld manager in a large USA ship yard. At the ship yard, I reduced the flux cored ship weld repairs by over 6 million dollars per ship. On the automation side I was the North American, Robot Weld Training and Application Manager for ABB Robotics. This company is one of the world's largest robot and engineering companies. At USA, General Electric, I was part of the Black Belt Team that went around North America optimizing welds. I was the Technical & Weld Training Manager for Praxair (Linde - Union Carbide. Plus I was the weld equipment & consumables, Marketing - Training Manager for both Airgas and AGA, two of the world's largest supplier of weld equipment and weld consumables.
In the last decade, while working as a weld process control consultant, I provided many international, MIG - Flux Cored and TIG weld process control workshops. For over a hundred of the Fortune 500 companies in 13 countries, I provided weld quality - productivity optimization for specific applications, and while at those companies, I provided employee training workshops.
The above MIG weld process control seminar, (photo above) was in Cleveland Ohio. The 80 participants were from Europe, Mexico, Australia, S. America and N. America.
Some of you may know
me from the 18 years that I wrote the QA Weld Column, in the USA, Weld
Design and Fabrication Magazine.
Perhaps you read the the sections I wrote on Laser and Plasma-Oxy Fuel Cutting, in the Thermal Cutting Section in the ASM Handbook, Ninth Edition, 1988.
 I have had over thirty published
weld magazine articles usually on subjects like the Simplification of Manual and Robot MIG / Flux Cored Weld Process Controls.
If you have Machinery Handbook gathering
dust on one of your book shelves, I rewrote the complete weld section.
I have written and published three books on Weld
Best Practices and Weld Process Controls.
a weld process and weld application engineer, I optimized MIG and flux cored processes
for approx. fifty years. Over 30 years ago I started to develop unique process control training
methods for both the MIG and flux cored weld process controls.
Ed provided manual and robot weld process training
and process improvements to GM Chrysler, Ford Toyota, Honda, BMW, Mercedes, VW,
plants. He has trained thousands of weld personnel in 13 countries. The training was mostly on MIG. FCAW, GTAW and Tip Tig appications from car palnts to nuclear plants A few examples are provided.
 Ed set
robots to weld the Corvette and Harley motorbike frames. He also set the robot
car seat welds for Toyota, BMW, VW and five other auto manufacturers.
When Ford and ABB was in trouble at the Dearbone Frame plant, Ed reset the Ford F-150 truck
frame lines and attained the highest quality and productivity ever attained by the Ford company.
When Imperial Oil and Pennsylvania Power and Light wanted it's pipeline welders
to stop using SMAW and use flux cored on the gas and steam pipelines, they used
Ed to train the union welders, supervisors and engineers.
 When Combustion Engineering wanted
to weld boiler tubes to headers with robots and the pulsed MIG process, which by the way is a very difficult
manual TIG application, Ed established the complex robot pipe MIG weld procedures
that passed all ASME section Nine requirements.
 When ABB CE Services Inc. decided to
use robots for the complex task of welding Nickel overlay inside generating plants
boiler furnaces they asked Ed to establish the nickel pulsed weld procedures.
 When MKS Instruments wanted to improve the quality of their micro Inconel
and stainless welds on their orbital and lathe equipment, Ed not only improved
the quality he provided over a million dollars of weld cost reduction.
When Textron had numerous problems on their Stingray armored tanks, Ed managed
the complex MIG repairs on the 270k tensile tanks in Thailand.
Welding Services (WSI) in Atlanta, wanted improved, automated, Inconel / stainless
clad welds for boiler water wall overlay applications, in a few months, Ed developed
a new MIG patent that reduced the overlay costs by 28%.
has written three books on MIG and flux cored weld process controls, and
produced unique MIG / FCAW best practices / process control training programs.
the nineteen eighties, Ed developed the "PocketWelder" the worlds
first electronic hand size weld data unit.
eighteen years, Ed has answered over a thousand weld questions in his welding
QA column in the "Weld Design Fabrication" (40,000 readers A
Ed has had more than 30 articles published on
the common welding and cutting processes. MIG process.
you examine the new "Machinery Handbook", >25 edition in
Barnes Noble, look at the way Ed wrote and simplified the MIG and FCA weld sectionS.
Perhaps you have read have the American
Society Metal's book, Ninth Edition "Thermal Cutting Section" (laser-plasma-oxy
fuel) you will note how Ed simplified this complex section.
Ed set the first robot
welds for Large Pipes.
In the nineteen nineties, Ed set the above ABB robot to flux cored weld a 40 inch pipe line welds
without weld defects. Thanks to the flexibility of the six axis robot and the
speed it can attain between welds, in contrast to traditional automated, mechanized
pipe weld equipment the robot reduced the total pipe weld cycle time by approx.
40%. Check out Ed's 1997 Robo Pipe Rig in the pipe and flux cored section.
& MIG welding in the Power Industry:
ABB Combustion Engineering. Ed acting as a weld process control consultant, was the first person and
still the only person to successfully set Rrobot Pulsed MIG welds on ASME Boiler Tubes
to the Boiler Header The robot welds consistently met section ASME 1X weld and radiograph
weld requirements. This diffificult all position, application, is typically carried out by highly skilled
manual TIG welders. Keep in mind at that time, the use of MIG welding was frowned on in the power industry.
cut through North American
MIG gas confusion.
to early 90s: In his role as a technical product manager
with two of the largest weld distributors in North America. Airgas and AGA, Ed
knew that the major gas companies such as Air Products, Linde, Carbonic and Liquid
Air in their process ignorance or
greed were marketing three part MIG gas mixes
that simply provided no real world weld benefits.
As a marketing manager with Airgas and AGA Ed worked
at cutting through the extensive salesmanship involved in MIG gas selection and
introduced to the market place three very practical, easy to identify,
two component gas mixes.
SteelMix, StainlessMix and AlumMix.
Ed developed and introduced to the North American MIG welding
market the following
important MIG gas mixes.
The multi-purpose argon - 15% CO2 mix for all carbon steel applications.
The multi-purpose argon - 2% CO2 mix for all MIG spray, short circuit and pulsed
stainless and duplex applications.
3] The argon - 1% CO2 mix for all MIG spray and
pulsed nickel alloy applications.
4] The argon - 1% CO2 and nitrogen mix
ABB Combustion Engineering. In a consulting role Ed was the first person to set
robots to pulsed MIG weld Inconel clad overlays on boiler tubes, inside the boiler.
As welding Manager at Welding Services, (Aquilex) Atlanta,
Ed provided a new approach to automated MIG Clad Welds
2006: Welding Services (Aquilex), 2006.
As the welding manager,
Ed changed the standard MIG clad method utilized around the globe to apply Water Wall MIG cladding
using Inconel and austeniitic MIG consumables. His new patented pulsded MIG procedures on this
automated weld application method reduced costly Inconel overlay clad weld consumable
consumption by approx. 28% per square foot. In contrast to the global standard inconel / stainless clad industry weld practices,
his new MIG weld method produced (photo above) produce a far superior
clad weld quality, less weld defects,
lower stresses and much less tube distortion.
Electro Slag Cladding changed to Pulsed MIG Patent developed by Ed Craig..
In the refinery
industry, pressure vessels used in high temp, high pressure "hydrogen"
surface such as hydrocracking and hydrotreating are usually constructed of low
alloy high strength steels. To overcome corrosion areas, clad welds can be applied
to the wasted areas. The most common cladding process utilized is the ESW process
using strip E309 / E347 electrodes. The 309 electrode may be used for the first
layer and typically the 347 or 347L is required as the clad surface layer. Typically
a 347 clad surface with a specific chrome and ferrite content is required.
Ed replaced Electro Slag Strip Cladding process with procedures he developed with
the much more cost effective Pulsed MIG Clad Process.
2005 Ed provided his client WSI with a single pass MIG clad method that will provide
the desired 347 clad weld quality and ferrite levels of 5 to 8% at only 30% the
cost of the traditional, global ESW strip clad weld costs.
the Boiler Wall Insulation
Stud Weld Process
with MIG Spot Welds.
Patent: When applying insulation to global boiler walls, the typical global approach
is too attach costly studs to the boiler steel structures and the insulation blocks
would have a steel bracket that attached to the studs. Ed developed and designed
for a client, a MIG spot process method that welded the bracket eliminating the
stud costs. This process was patented in 2006.
major weld quality - productivity FCAW resolutions, for a ship yard that was loosing > 8 million dollars in weld rework per-ship.,
Aker Kaverner ship yard wanted to reduce the multi- million dollars FCAW weld
rework it spent per-ship, they asked Ed to develop an all position flux cored
process control program to minimize the
common lack of weld fusion, slag entrapment and porosity associated with vee groove
welds and ceramic backing. His unique, eight hour training program focussed on
process control settings and technique requirements necessary for optimum, all
position weld quality / productivity optimization. In a six month period, the
weld rework improvements associated with the training program were remarkable,
achieving a saving of more than four million dollars per ship.
To reduce the tremendous flux cored weld and weld rework costs associated with
vee groove weld joints on plates 12 to 25 mm thick, with ceramic backed weld
gaps 8 to 25 mm, Ed and his good buddy Tom O'Malley took five days to produce
new, all position weld procedures that resulted in approx. a 50% decrease in
the typical labor and consumable costs required for the over sized vee groove
has spent decades solving Miller, Lincoln, Hobart, ESAB,
pulsed MIG equipment problems and never got a Hall Mark card from any of these companies.
DECADES OF PROCESS IMPROVEMENTS: Perhaps the biggest contribution Ed made to
the welding industry from 1987 to 2007 is the fact that in that time period he
assisted over 1000 companies in North America. The companies had purchased pulsed
MIG equipment or Inverters for either their manual or robot cells. These weld
shops had one thing in common, the weld shops could not produce consistent, stable
arcs on carbon steel welds. The MIG equipment manufactures who sold the pulsed
equipment provided no solutions and when I visited the weld shops I would turn
the pulsed modes "off" and reset the welds with either the traditional
CV short circuit or spray transfer modes.
2007, Microsoft takes responsibility for it's manufacturing problems
and plans a recall that will cost them 1.5 billion for their X box electronic
issues. From 1987 to 2007, I cannot recall
Lincoln, Miller, Hobart, ESAB or Panasonic providing a single recall of their
less than durable, highly erratic pulsed MIG equipment. I also cannot recall getting
a thank you note from these MIG equipment manufactures for my solutions (switched
their pulsed modes off) to "their customers" and for rectifying the numerous,
global, pulsed weld problems caused by their faulty electronic pulsed equipment.
following are a few
Ed's weld applications.
Ed convinced the GM engineers in charge, that robots
using the MIG process could do a better job on the Corvette than the manual workers
using the ridiculous self shielded flux cored wires. He first trained the Corvette
manual welders on the MIG process and then encouraged GM engineers to actually use a robot and set the MIG
weld data for the Corvette.
Power company was the first company in the world to utilize miniature robots inside
power station boilers. The robots ran along a gantry attached to the boiler walls.
The robots were required to MIG clad weld the water wall pipe using either austenitic
or Inconel consumables. In the 1990s ABB requested that Ed establish the pulsed MIG robot clad weld
procedures for this unique application. I set the welds and received a
great tan from the robot weld rays as they reflected of the boiler walls.
Caterpillar decided to weld the world's largest truck with robots, Ed was asked by the ABB robotics Div to establish the multi-robot spray transfer weld procedures.
A job like this can be made with three weld procedures, do you know what the are? Ed's robot process control training resources will show you.
When Harley redesigned it's bike frames
for its ever increasing girth customers in the late nineties, they needed bike frames in which 400 pounds was considered normal. With the assistance
of a highly qualified ABB programmer, Ed established the new robot frame welds.
The welds had over 200 robot program points and he did this project from scratch
in approx. five hours. Ed gave the Harley managent the potential for great weld productivity
and weld quality they had never achieved before,.
When Volvo required MIG welding robots to weld
it's giant, difficult to weld truck cabs, Ed set the robot MIG data and resolved
their robot weld issues and when Fruehauf wanted robot welds that would last a million miles on their trucks they asked Ed to do them.
When Case and John Deer had issues with it's robot welded tractor cabs and parts they requested
that Ed resolve the issues .
Ed showed the Imperial Oil / Esso pipe welders that Jesses an 11 old boy could weld pipe using the MIG and FCAW process. Imperial Oil wanted their pipe weld subcontractors to increase weld
productivity on theit Nat gas pipe line welds made at the Cold Lake project in Alberta. Ed developed the training program and then trained their key weld personnel to use the MIG and flux cored process without playing around with weld controls. Ed
later established the flux cored automated pipe weld procedures for the Cold Lake 6 to 20 inch
pipes. (See one million dollar savings article in the pipe weld section)
When Club Car one of North
Americas leading golf cart manufactures built the world's first fully automated,
multi-robot MIG weld line for it's unique "aluminum" cart frames, it
could not afford to have one robot go down with weld process issues. Ed set the
pulsed aluminum MIG data for the four robots that worked together on this line.
This line had less weld issues than a typical multi-robot line welding steel frames.
When Haynes Lemmerz, one of the world's largest
producers of aluminum and steel wheels was having Miller, Maxtron / Invision pulsed
weld issues on their automated MIG weld lines, Ed quickly provided the weld solutions
necessary to optimize the weld quality and increase productivity
When the new VW Beetle prototype car seats were being built in
Mexico by Johnson Controls there were extensive robot weld equipment problems.
It took me four days to eliminate the robot weld problems and increased the weld
production by 30%. In 2005 when VW Mexico had problems with galvanized door components
that were welded with Lincoln self shielded wires, Ed changed the process to MIG
and reduced the rework from 55% to 5% and increased the productivity by 10%.
FOLLOWING IS AN EXAMPLE
WHAT ED DID BEST.
Motors installed a new multi-million dollar, torque converter, MIG welding line
at one of it's Midwest manufacturing facilities. The line was to produce approx.
1000 convertors daily.
the line integrator had built and installed the torque converter MIG welding lines,
I was asked by the GM engineer responsible for the project to address the automated,
pulsed MIG weld quality issues caused by the new Lincoln,
PowerWave weld equipment. The weld reject rate was daily in the 5 to 10
percent range, not bad, but 100 ruined torque convertors every day was costly.
less than 16 hours at the plant, I switched the inconsistent pulsed mode off,
and established more effective, traditional MIG spray transfer weld parameters
for the torque converter welds.
The new weld procedures I generated,
along with the weld process controls that I implemented, changed the daily weld reject rate to "zero" . As a bonus to
GM, I also increased the daily mechanized weld production by twenty
Note: The optimum weld results that I attained at the
GM plant could have been achieved with traditional MIG equipment that would have
cost GM one hundred percent less.
weld process changes for the GM torque converters, saved GM millions annually.
The cost to GM for Ed' s weld expertise and process control was less than fifty
percent of the cost the over priced Lincoln PowerWave power source.
ED'S MANUAL & ROBOT WELD
CONTROLS, & BEST PRACTICE RESOURCES.
ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES.
A FEW OF IS PROJECTS THE
FORD F150 FRAMES -
VOLVO CABS - CORVETTE FRAMES -
HARLEY FRAMES - NEW BEETLE SEATS
WELDS ON THE CATERPILLAR
WORLD'S LARGEST TRUCK.
Ed knows how to set optimum weld process controls. If you are interested
in his MIG and Flux cored weld process control training programs, click here.
For MIG and Flux Cored process
expertise visit www.weldreality.com
You can contact Ed Phone 828 337 2696.
(USA. Eastern Standard Time).