a weld process and weld application engineer, Ed has optimized MIG and flux cored processes
for approx. fifty years. Over 30 years ago Ed started to develop unique process control training
methods for 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.
FCAW on Large Pipe.
During 1997, 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.
and MIG welding in the Power Industry:
ABB Combustion Engineering. Ed acting as a consultant was the first person and
still the only person to successfully set a robot to pulsed MIG weld Boiler Tubes
to the boiler header and consistently meet section ASME 1X weld and radiograph
weld requirements. This application is typically carried out by highly skilled
manual TIG welders.
cut through the USA
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 Mgr at Welding Services (Aquilex) Atlanta,
Ed provided a new approach to automated MIG Clad Welds
For Welding Services (Aquilex), in 2006,
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.
Ed replaced Electro Slag Strip Cladding.
the more cost effective Pulsed MIG Clad Process.
Patent: 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.
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.
Boiler Wall Insulation
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 millions of dollars profit 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.
DECADES: 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 of
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 .
When Imperial Oil / Esso wanted to increase weld
productivity on its natural gas pipe line welds at the Cold Lake project in Alberta, Ed trained their welders to use flux cored wires without playing around with weld controls and
later established the flux cored automated pipe weld procedures for thir 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 process issues on its automated welding lines, Ed 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 CRAIG 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 HIS 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).