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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

Ed Craig's Weld Expertise.

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.



As 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.

[] When 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%.

Ed has written three books on MIG and flux cored weld process controls, and produced unique MIG / FCAW best practices / process control training programs.

In the nineteen eighties, Ed developed the "PocketWelder" the world’s first electronic hand size weld data unit.

For eighteen years, Ed has answered over a thousand weld questions in his welding QA column in the "Weld Design Fabrication" (40,000 readers A MONTH) magazine.

Ed has had more than 30 articles published on the common welding and cutting processes. MIG process.

When 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.


Robot 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.


Robots and MIG welding in the Power Industry:


1998. 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.


Ed cut through the USA
MIG gas confusion.

1980s 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.

1] The multi-purpose argon - 15% CO2 mix for all carbon steel applications.

2] 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 for duplex.

2001 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


2006: 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.
With the more cost effective Pulsed MIG Clad Process.



2005. 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.

In 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.

Ed replaced Boiler Wall Insulation
Stud Welds with MIG spot Welds.

2006: 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.


Ed provided major weld quality - productivity FCAW resolutions, for a ship yard that was loosing millions of dollars profit per-ship.,


2007:When 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.

2007: 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 applications.

Ed has spent decades solving Miller, Lincoln, Hobart, ESAB,
and Panasonic pulsed MIG equipment problems.


TWO 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.

Weld technology accountability: During 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.

The 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.

ABB 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.

When 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%.


General 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.

After 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.

In 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 percent.

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.

The 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 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.

Ed lives in Asheville.
North Carolina.

For MIG and Flux Cored process
expertise visit www.weldreality.com

You can contact Ed Phone 828 337 2696.
(USA. Eastern Standard Time).