Emily Craig, Sr Weld Engineer

Asheville, NC. Will Relocate.

ad1rd5@r.postjobfree.com / 828-***-****

www.linkedin.com/in/emily-craig-a793688

Website: www.weldreality.com

Summary:

For the last three decades, I have provided hundreds of companies in 13 countries with resolutions to their Manual, Automated, Robot weld quality & productivity problems. I established unique Weld Best Practice Process Control Training programs with GMAW - GTAW – Flux Cored. Hot – SMA – Hot Wire TIG – TIP TIG – SAW – Resistance Welding - Brazing.

Diverse Industrial Weld Application Experience. I was requested to solve weld quality / productivity issues on numerous, complex weld applications, such as weld joint designs for the Mars Orion Spacecraft. – Develop Welding Procedures for the first USA Tokamak Fusion Plant, (MIT / CFS project). - Developed Welder Training Programs and Procedures for USA, Navy Frigate Aluminum weld repairs. - Develop procedures for F15 Fighter Plane engine cast weld repairs. – Develop Weld procedures / training programs for LNG Cryogenic Vessels. - Train welders for Railroad Tank Car construction. – Develop procedures and training programs for numerous Nuclear & Fossil Fuel Plant Vessel / Pipe welds / Clad Applications.

Codes and Weld Specification Expertise. Was requested by the American Weld Society (AWS) to lead the committee on developing the AWS GMA (MIG/) Specifications. Advised AWS committee on development of Gas Shielded Flux Cored Weld Specifications.

I have extensive working knowledge and experience with the following weld codes and specifications. ASME - AWS D1.1 / D1.2 D1.3 / D14.1 / B2.1 - API - SAE – NAVSEA / E.B Weld. I am also familiar with the NADCAP and ISO accreditation requirements for process improvements with Aerospace and Defense companies. I managed and generated the necessary paperwork and requirements to qualify any welds, qualify and train the welders, produce procedures, and establish best weld practices.

EDUCATION:

Stretford Technical College – UK

City Guilds 4 yr. Welding & Metallurgy – 1984

PROFESSIONAL DEVELOPMENT:

Ohio State University – Laser Weld & Cutting Program

Ohio State University – Advanced Robotics & Weld Program

Thermal Dynamics – Advanced Plasma Welds & Cutting

MK Products – Orbital, TIG & Plasma, Tube & Pipe Welds

Note: My resume is likely a little different than others in that my working career is extensive with a mix of consult and full-time roles. I am looking for a full-time position & prepared to relocate.

2

WeldTrain International.

My Consult Comp. Contract Positions. 2011 – 2021

Commonwealth Fusion - Massachusetts Institute of Technology, MIT. Boston.

Position Weld Manager.

Manage all weld decisions for building the First US Tokamak SPARC FUSION Reactor. During the development of their SPARC Tokamak Fusion reactor, CFS / MIT built and tested the world’s strongest, Cryogenic, Superconductor Magnets. Their 20 Tesla magnets, delivered 40,000 Amps operating at - 440F. The Cryogenic Magnets will be a few feet away from the 100+ million-degree plasma. The Reactor components require extraordinary engineering weld quality & distortion requirements for the mostly Austenitic, Nitronic & other alloys. Apart from achieving a fusion vessel weld quality that will never require weld repairs, the metals and multi-pass vessel welds also have Cryogenic, Magnetic Permeability, Radiation, and stringent weld Distortion Tolerance control concerns.

My weld responsibility for the Tokamak Reactor. Develop the weld joint designs. Select the most appropriate welding processes and consumables. Develop welding qualifications & procedures. Advise supply chain vendors on the welding processes, procedures / practices to be used. Develop weld process control training programs required CFS vendors.

Note: In 2022. CFS received 1.8 billion dollars funding from Bill Gates to complete the first Tokamak plant.

Consult Contract. Lockheed Martin / United Technologies. Aerospace Sector. CT. USA.

Project: Advanced Engineering Team Weld Specialist for Orion Moon / Mars Space Project.

Contract Position: Contract Senior Weld Eng.

Requested by Lockheed / UT to assist in improving their engineers and their supplier weld joint designs, and resolve weld issues with the automated Hot Wire GTA, Laser & Electron Beam welds on the Orion. This space craft will one day land on the Moon & Mars. I followed NASA mfg. protocols and guide lines to implement the weld design changes.

Consult Contract. General Electric.

N. American Advanced GE Mfg. Engineering Team.

Position. I was their Black Belt Weld Eng. Team Leader / Trainer.

Over a 3-year period, at many of the GE N. American / Puerto Rico Mfg. facilities, I was requested to provide mfg. & weld process quality & productivity improvements with MIG – TIG – Plasma - Resistance & Laser, manual and automated welds. At each location within 3 days, my changes would provide dramatic weld quality and productivity enhancements, and enabled substantial weld cost reductions.

After implementing process changes, I would rewrite and requalify the weld procedures. Provide the required weld process controls & best weld practices. Then follow up by training the GE weld shop employees and their responsible engineers / managers on the new requirements necessary to maintain the weld quality and productivity.

Consult Company: Cameron - Schlumberger Houston. Sub Sea Valve / Components Mfg. Leeds UK.

Position. Weld Project Mgr.

Contract. Requested to resolve Sub Sea Valve Clad Weld issues.

Schlumberger requested that I assist their Leeds plant as their weld engineers were having costly automated GTA Hot Wire CLAD weld rework issues on Inconel / stainless Sub Sea Valves. In a month at Cameron, I provided the necessary robust weld solutions to reduce their Valve Bore Hot Wire GTAW clad weld defects from 10% to less than 1%. - I recommended extensive automated HW torch modifications to improve weldability. -My new Hot Wire TIG clad weld procedures enabled an increase in production by 25%. - Then provided plant weld personnel with the Process Controls / Best Practice Training required.

3

Aker Kvaerner Ship Builder. Philadelphia Naval Shipyard.

Contract Position. Shipyard Weld Manager.

While building container ships / oil tankers, Aker averaged approx. 8 to 10 million dollars over budget per-ship weld repairs. Aker requested that I take this temporary management position to improve the ship yard training program, reduce the ship’s flux cored plate weld rework and improve the Flux Cored and MIG weld productivity.

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I updated the yards welder training program with emphasis on providing all the weld personnel, supervisors and managers with Weld Process Controls and Best Weld Practice expertise for flux cored process optimization. I used the training programs I developed for the 2-day program. I developed & qualified new flux cored weld procedures. Within four months, my procedures / training programs, (verified by the yard’s QA - Weld Audit Department) revealed;

I reduced the yard’s flux cored weld rework & NDT costs per-ship by approx. 70%.

I increased the daily manual flux cored weld production by approx. 35%.

I reduced the annual shipyard weld equipment & consumable costs by approx. $750.000.

I reduced the annual yard weld equipment repair costs by a projected $450.000.

Consult on USA Navy. Aluminum Frigate Weld Repairs

Company Gulf Copper Dry Dock and Rig Repair Galveston, TX.

Contract Position Training and Procedure Development Mgr.

Gulf requested that I develop NAVSEA, all position, Pulsed MIG, Aluminum Weld Repair Procedures for damaged Navy Frigates located at Guam Naval Base.

In less than two weeks I established and had qualified approx. 20 all position, full penetration, aluminum, Pulsed MIG weld repair procedures on aluminum parts ranging from 16 gage to 5/8 thick.

I recommended the optimum weld equipment and consumables for the project.

I developed a training program and trained the repair welders and supervisors in the required weld process controls and best weld practices necessary for process optimization, and provided the training necessary for the welders to pass the NAVSEA Aluminum Welder Qualification Requirements.

Consult on George Bush, Aircraft Carrier Weld Repairs for Gulf Copper Texas.

Position. Project Senior Weld Eng.

Contract Project. Stainless PIPE Weld Repairs.

Requested by Gulf to create a Weld Repair Proposal for the George Bush Carrier, stainless pipe weld issues that were due to Root Crevice Corrosion, (CC). This type of corrosion was extensive on the Aircraft Carrier and on other Naval vessels. As the Gulf Copper Weld Process Control expert, I provided the extensive weld repair proposal, along with the required weld qualification requirements and procedures. I also provided the welder training proposal requirements necessary to not repeat the CC issues.

Consult Defense Contract: Textron Marine and Land Systems.

Position Project Weld Repair Manager.

Project. Stingray Armored Tank Repairs, Thailand.

The Textron Florida Tank mfg. plant created issues that required major field weld repairs on their armored tanks sold to the Thai Army, (200 plus million-dollar project). Extensive cracks were revealed in Thailand on most of the tanks sold. I was asked to go to Thailand and manage the extensive weld repairs. This complex project was made more difficult by the armored steel 270K tensile plates and as there was no electricity and no trained welders

At the Thai army base. In less than ten days, I established the MIG / FCA procedures and trained 20 Thai. soldiers who had never welded to become skilled with both MIG & flux cored. This enabled them to make the all position, extensive, armored plate weld repairs for 120 Stingray tanks.

4

Consult Contract: Exon. Alberta Tar Sands.

Position. Senior Pipe Line Weld Engineer & Project Training Mgr.

Project. Evaluate Processes for Manual and Automated Nat Gas Pipe Welds

Most of the Exon pipe welders were at that time highly qualified with SMAW (stick) welding and most had been reluctant to take up the more cost-effective Flux Cored and MIG process for the Nat Gas pipe welds. Exon arranged for me to have the SAIT facility in Calgary Alberta to do the training.

I provided both Manual & Automated MIG & flux cored pipe welder training for the pipe welders, supervisors, and engineers to meet the required API welder qualification requirements. My training was on the Exon Nat Gas pipe

sizes 10 to 100 cm diameter.

My hands on training also included pipe weld process controls and best pipe weld practices that enabled the participants to quickly learn and optimize their flux cored and MIG pipe welds

I provided new MIG / FCA pipe weld procedures for pipe welds.

I then trained all the personnel on how to pass the API 6G pipe welder qualification tests.

I provided Exon with all the necessary weld qualification and weld procedure data.

I was notified later that after a 6 months audit on my training results. Exon senior engineering management reported that the total annual weld savings that I generated from this training from one of their 37-field pipe weld crew team, was approximately $2 million annually, (they employ many of these teams).

I followed up a year later & trained the contractors on Automated FCA pipe weld equip.

FULL TIME POSITIONS.

FULL TIME. TIP TIG USA. 2008 - 2011

I created TIP TIG USA to bring the latest advanced GTA (TIG) weld process to the N. American & Australia

Info at tiptigwelding.com site.

The regular GTA (TIG) process has evolved into Semi-Automated, fully automated process called TIP TIG. Since the 1940’s, TIG has been the prime arc process of choice for many code applications. TIG requires the highest welder skills. It produces high weld heat input and from a weld cost perspective, creates the highest weld costs from the lowest weld deposition rates.

Note TIP TIG & SPACEX. I introduced TIP TIG to Space. In 2019 - 2020, SpaceX purchased > 70 units and made TIP TIG their weld process of choice for their rockets. This process enabled them to get through the NASA destructive rocket tests. I consider myself one of the leading global experts on a process which will be the evolution of GTA.

FULL TIME ABB Robots & Flexible Automation. 2002 – 2007

Robot Arc Weld & Cutting Div.

Position. ABB Corporate Robot Weld / Training Manager.

As the ABB Robot Senior Weld Engineer and Corporate Weld Manager, and in my role as a weld consultant in more than 13 countries, with hundreds of companies. I was requested to optimize Robot MIG - TIG - Flux Cored – Hot Wire GTA weld quality and productivity. I would provide the robot process optimization requirements or improvements, then provide the hands on and classroom training with a diverse range industrial complex weld application.

I established & set the world’s first robot welds on 40-inch (100cm) pipes used n the oil industry.

I was requested by Caterpillar to establish robot welds for the world’s largest trucks.

I established optimum robot welds for pipes and casings on Exon Oil Rigs.

I developed unique robot TIP TIG weld repairs (superior to TIG) for US fighter plane cast engine blocks.

I provided optimum robot Hastelloy welds on Gas Turbine parts.

I established the first multi-robot cell application, aluminum club car golf carts.

Requested by Ford to provide weld resolutions and establish new robot welds on the Ford F-15 truck frames.

Requested by Harley to establish the robot frame welds on Fat Boy bike.

5

FULL TIME. Weld Services Inc. WSI (AZZ) Atlanta. USA. 1998 - 2001

Position. Weld Mgr.

AZZ employed more than 500 field welders to provide shop / field, power plant weld / clad plant welds. AZZ would annually use approx. one million pounds of Stainless / Inconel weld wires cladding more than 70% of the globes Water Wall boilers.

Responsible for GTA / Automated GTA / Pulsed MIG welder training, weld procedures, weld procedure qualifications, weld equipment design and weld process and equip. purchase recommendations.

I developed a new boiler water wall, Inconel – Stainless, Automated Pulsed MIG Clad Weld procedure which was patented by AZZ in 2007. My weld patent reduced the typical amount of Inconel or stainless cladding consumables by 30%. This patent also allowed an annual weld consumable cost savings of approx. 6 million dollars. The superior pulsed MIG clad weld quality also provided many Boiler Water Wall benefits such as improved corrosion resistance and less wall distortion.

Provided plate, pipe, tube and pressure vessel, manual and automated weld training

Provided Weld Safety training

Guide the weld team in ensuring highest, uniform weld quality & productivity.

Provide coaching to enable career development & recruit and train top weld talent.

Manage shop floor weld equip. layout including tool management, FOD mitigation, part control.

FULL TIME Full Time. Airgas. Philadelphia. 1996 - 2000

World’s Largest Weld Distributor.

Position. Corporate Weld Product & Weld Training Mgr.

I was responsible for new Weld Equipment Selection sold by Air Gas.

Responsible for training approx 2000 weld salesmen in welding / cutting optimization.

Provided weld / oxy-fuel cutting process workshops across the USA,

Provided weld quality & productivity resolutions & training hundreds of Airgas fabrication / mfg. customers.

I developed and introduced 4 of the top selling MIG gases used in both the US and Canada.

FULL TIME Full Time. AGA Cleveland Ohio. 1992- 1996

World’s Largest Weld Distributor.

Position. Corporate Weld Product & Weld Training Mgr.

Same role as at Airgas above. 4 of the top selling MIG gases used in both the US and Canada.

Full Time. Linde / Union Carbide. 1987 - 1992

Weld Training Mgr.

National Linde Training Mgr. Cn. Developed Weld & Cutting training programs & provided training to approx. 1000 Linde reps. on all the Linde equipment. Provided weld shop solutions / training to Linde customers across N. America.

A Shipyard Reference from a General Dynamics Weld Foreman Mr. Ephron Williams. GD. NASSCO Shipbuilding. Emily, having instituted your unique Weld Process Control – Best Weld Practice Flux Cored and MIG training programs at our NASSCO General Dynamics facility, I wanted to let you know the following results. At this location we are striving to improve our weld quality and I was hired in the middle of extensive poor, costly weld performance on a major, USA Navy CVN contract. Thanks to your flux cored and GMA and TIP TIG Training programs, we have greatly reduced our weld problems, and with these programs, we finally were able to understand that our approved NAVSEA weld procedures were far from optimum. With both our flux cored and GMA weld processes, we were using inappropriate weld practices with very low weld parameters, (outside your minimum optimum recommended range. We are now using your recommended WPC weld parameters and best weld practices & are changing our weld procedures to your recommendations. EW.

6.

A Reference from Schlumberger Sub Sea Company, Senior Weld Manager Mr. Clint Wildash. Emily. The Advanced Hot Wire GTAW weld process control training presentation you developed was brilliant. Thank you very much. Is it ok for me to circulate your Advanced GTA Training Program internally within Schlumberger organization for the education of our weld community? I look forward to deploying your training programs further within our business. Note: One Subsea Schlumberger in 2019, had a revenue of $33 billion.

A few Career Achievements outside weld shops:

Four Weld patents all directed to improving weld quality and production.

I developed four of biggest selling MIG gas mixes sold in North America, Europe and Asia.

For 18 yrs. Weld Design Fabrication Mag. advised over 80,000 readers QA Welding Column.

40 articles published on Weld Process Controls - Best Weld Practices.

Wrote 3 Books on Manual – Robot MIG – Flux Cored – Process Controls – Best Practices.

Wrote the MIG – TIG – Flux Cored and Laser sections in the USA Machinery Handbook.

Wrote the Laser – Plasma – Oxy Fuel (Thermal Sections) in American Society Metals Book.

Invented “Pocket Welder” world’s first-hand size, electronic weld / steels unit (AWS).

My Weld Patents:

[] 1996. Ceramic/Cu MIG gun contact tips to attain Higher Speed Robot MIG Welds 98.

[] 1997. World’s first “Portable Electronic Weld Data Unit, “Pocket Welder”.

[] 2006 New Boiler Water Wall Clad Weld Techniques for stainless and nickel MIG wires.

[] 2006 New Weld method for Clad Welds Hydro Cracking Vessels.

[] My web weldreality.com

Below a few of my Books & Weld Training materials.

I apologize for resume length. Regards Em. Craig.

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