What do you want in a welding book?

Ernie, you've gotten lots of good suggestions; let me take a different tack on this (no pun intended, of course!):

As a college professor, I've written a couple of textbooks. I have found it helpful to work on the book *as* I am teaching the course. (Not necessarily writing it as you go along--I did that once and about went under!) But you will think of many, many things that need to be in the book as you are working with the students. If you don't write them down immediately (or keep a pocket recorder handy and record a memo for yourself) they will be gone when you sit down to write the book. You may even be able to work out some sort of release form that would let you take pictures of actual student mistakes for use in the book (probably need to consult a lawyer and your school on that one). At the very least see if you can take pictures as a way of reminding yourself of things you need to address, even if you have to reproduce the mistakes yourself for the actual publication.

I say all of the above even if you are not necessarily intending this book to be a "textbook" as such. The textbooks for the welding classes at the community college are more than $100, so they have a pretty limited audience. On the other hand, you could write a book for more general consumption that would still be very useful (perhaps even more practically useful) as a supplementary textbook, as well as for a lot of folks who are not taking classes (or already have taken classes). BTW, I don't know how publishers are in this sort of field, but textbook publishers in the humanities often want to see a *textbook* actually used a couple of times in a class, and preferably by more than just the writer, before they publish it. A more general-purpose text does not have to pass that test, so long as you can sell the publisher on it. As to the latter, publishers normally want to see that you have the credentials and experience to justify the book; I think you could refer them to any member of SEJW and/or RCM for a resounding recommendation!

Finally, I'll chime in regarding including a DVD or CD. More and more publishers see this as a way of distinguishing their books from their competitors. I think the words of caution about producing a full-length video (DVD) are worth noting. On the other hand, short video segments could sure make a difference in the usefulness of the text. I'm thinking for example about the short video demonstrating how to feed a TIG rod through your fingers that you posted to the drop box a year or so ago -- something like that would be *very* difficult to convey in text, but was clear as crystal with even a low-resolution video. Short video segments like this would, I think, be much more feasible and affordable to produce, and probably as useful and maybe even more useful than trying to put together 2 hours of continuous video.

Hope this helps!

Andy

Reply to
Andrew H. Wakefield
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As an afterthought ... You might look at present day examples. I do know that AWS is developing instructional materials for their approved instructors. Locally in B.C. Canada we have module books that are used in a vocational setting. ( currently being revised)

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I know Alberta also has a considerable library of material for their vocational programs. There is no use re-inventing the wheel and at the same time reference materials also tell you what not to do in designing the presentation. Randy

Reply to
Randy Zimmerman

Here's more million dollar advice. There are a lot of welding books out there. If you want to make money, write a book about how to get acceptable results with the sleazy HF-like welding units. There are a lot more people with the cheap machines than 600 Amp TIGs.

Kevin Gallimore

Reply to
axolotl

Decades. We're greedy folks. Then again, that's why I offered to beta test/proofread it for him. ;)

--- Annoy a politician: Be trustworthy, faithful, and honest! ---

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Comprehensive Website Development

Reply to
Larry Jaques

Now that I have read all the posts. I would like to see a DVD / book that work hand in hand as a follow along so you can use the book to follow on and then take it to bed or work as a refresher to read. Some people do books and videos on a subject but they are now saying the same or it sounds different. I for one watch better that reading, but if I see it on video or DVD then read it, it will soak in better. This coming from a beginner. If you want to teach them right, you need to start with a beginner so you can groom them the ground up. I like reading this news group. It does help with info. Right now all I have is O/A and wire feed but I do buy books and videos on all I can.

Don D.

Reply to
Don D.

Oops, hit the wrong button and sent an empty reply. Sorry 'bout that!

While I understand that you need those books for teaching, it's already been done. I'm sure your versions would be better but what I'd really like to see is something more along the lines of a "tricks of the trade" or "bedside reader" type of book that covers all the cool tricks you've taught us over the years such as the pencil and washer trick to learn TIG torch movement, how to smoothly advance filler in your hand and the nice "corner square" you told us about. The kinds of tricks that aren't in books already. I've seen several books along those lines for machinists but not for welders/weldors.

Best Regards, Keith Marshall snipped-for-privacy@progressivelogic.com

"I'm not grown up enough to be so old!"

Reply to
Keith Marshall

...

I read all the responses, and don't recall "how to do destructive testing" mentioned elsewhere. I don't think it takes much explaining on the "how", so fitting it in shouldn't be a problem. (But as JohnM wrote, "You're gonna need wheels for this book if you take even half the advice you've got so far." Maybe that could be a welding project in the book :) Anyway, I think there should also be at least a few paragraphs about the "why" of destructive testing, and how important it is, and how informative and surprising it can be, and why destructive testing should be done by the maker rather than the end user. :)

Do you plan to mention or cover any nondestructive testing methods?

-jiw

Reply to
James Waldby

OK Guys after reading the responses I am starting to get an idea of what direction I am going to take.

I am thinking I will follow the pyramid approach. The traditional way to write newspaper articles is to give the most important information at the beginning and then work your way back so the last paragraphs of the article give the greatest detail. I can see this working for welding instruction. Each section would give you the basics up front, of say MIG, like how to set the machine and move the gun, and then digress further as you go into it towards WHY you do those things. If you can catch on fast you don't even have to read the whole section to get started.

First I am going to do a general welding book that covers GAS, MIG, TIG, STICK, Fuel-gas cutting, and Plasma cutting.

A second book will cover just TIG with a lot more info on fabrication.

Each book will have a large reference section in the back, or maybe I will have a third reference book, separate from those 2.

As to the DVD/Video tape, I will do one that accompanies each book. The videos will be available by themselves as well, but will work hand in hand with the books.

I wrote a welding book many years ago, but it was specific to the theatre industry. I never got it published, but it taught me a lot about the publishing world. I have an offer from a fellow who runs a printing house to offer print-on-demand services. So there would be no large upfront cost for printing. As each order comes in, the book is printed and sent out. It seems the safest route. There is a shop here in Seattle that does nothing but DVD and CD-ROM production, called Discmaker. They can easily handle mass producing a DVD, once I have the content.

Feel free to keep making your suggestions as to content. I will keep taking notes.

Reply to
Ernie Leimkuhler

That actually sounds very good. Now you just have to -write- the thing!

Reply to
zackbass

Why not (also) re-view that one and, after any needed updates, publish it the same way?

Reply to
RAM^3

A couple of things that others have not mentioned.

One would be to include a photo of a MIG weld that looks good but is essentially a bead not fused into the parent metal and a photo of how it fails a destructive test. It would be good to get a photo of the weld being made. And of course the same photos of a good MIG weld and how it passes a destructive test.

Another topic to cover is low hydrogen rods. Which metals require that the rod be really dry and what metals you can weld with 7018 that has not been kept dry. And something about rod dryers. I am not convinced that the light bulb in a compact refrigerator are really good enough for when you need Low Hydrogen rod.

Another whole book you could publish would be projects as making anvils, welding tables, go karts, sculptures. You might start taking pictures of things your students build and get releases now , just in case you ever decide to write a second book.

Dan

Reply to
dcaster

One of the things lacking in almost all of the welding books are good step-by-step excercises and projects for trying out and refining the skills and methods chosen. I love the idea of a companion DVD to demonstrate what is being written about.

Also, don't bog the reading down with lots of jargon and industry terminology. The books I have found which mostly seem targeted at formal classrooms are heavy on jargon and light on practical applications.

Make it fun and interesting to build one's skills.

John

Reply to
John Horner

Ernie Leimkuhler wrote in news:ernie- snipped-for-privacy@news1.west.earthlink.net:

One thing that came to mund, was that American writers (probably some liability thing) seems obsessed with safety, please dont start with 5 pages on how to put the plugg into the poweroutlet (I have litterally seen such a book), and we also know we´re not supposed to do welding on our tothfillings :-) Henning

Reply to
henning wright

Ernie, First I would like to thank you for all the free information and tips I have personally learned from you off of this forum and the videos in the drop-box (i.e.- filler rod deposit & motions) Since I joined the AWS recently and got the Ninth edition vol. two I can't really put it down. I started with Mr. Finch's book as I'm sure a lot of us have. Very limited and in my opinion. And very "Look what I did" grandiose style of writing that seemed almost insulting at points. If you were able to replace that book with your teaching knowledge and history of the science as applied by your hands and teachings I would love to see content blended such as that of what the AWS book provided (I really can't thank Artemia Salina for the post on

06.06.2005 for the findings) If you could possibly integrate in whatever edition or even as a side line - A video series as well as text would be great. The only book I have found worth a poop on TIG is Miller's GTAW book my dealer kindly gave me with a few thousand dollar sale. Again, when I got my 210 Miller included a MIG video tape- a picture is worth a thousand words but a video has been priceless when I was without a mentor starting out. Whatever the book (and hopefully video(s), I'm sure it will accelerate and help many, myself included. I don't know if a book sided one for the private market and one academic is worth your time but there is a difference in content in every book I have from school and from real life. Just a thought sir. Not everyone does this for a living and teaching by example can be done in video and text, Heck, I did it! (Then I hired a hillbilly who could weld like a machine!!)

Wish you all the best and if needed, just ask for photo's with release documents (Gratis of course). I'd be glad to contribute my mistakes for others to avoid, plenty of blunders and good results from my race shop. A lot of folks could use a lesson on a class D Fire extinguishers existence as well. (Or refer to UL).

Rob Fraser

Fraser Competition Engines Chicago, IL.

Reply to
RDF

Because I re-viewed it a year ago and realized how bad it was now that I know so much more about commercial welding.

I may rewrite it so it is much better, but one book at a time.

Reply to
Ernie Leimkuhler

The more I think about it, the more I realize there is to teach about fitting parts to be welded. What fixtures are easy to make and invaluable, what clamps work well, techniques for welding things when they have to be flat or they have to be square or they have to be at a given angle. I learned really a lot about fitting structural steel when I worked as a shipfitter for 10 years once, but fitting a framework which will support a generator in the engine room of a ship isn't quite like building say a display table to go in the lobby of a museum. What I didn't learn back then was how to use elementary heat forging to fix weldments that got pulled a little out of alignment. Now I just estimate a couple of degrees for the weld to pull something, weld it up solid, check it with a square, and bend it cold or forge it to tolerance whatever that is. I have never seen anything like that in a book, that's where a blacksmith/artist/craftsman can bring real value to a welding text.

Grant

Ernie Leimkuhler wrote:

Reply to
Grant Erwin

Something in there about how to extinguish yourself when you catch on fire might be nice. And a few projects to make some basic tools like an anvil or welding table. Maybe an exercise to help a new student go about determining proper machine settings for a rod when not told up-front. I gleaned a lot from my welding class one week when I didn't bother looking at the chart and just experimented until I found a good setting. After that I was better able to fine-tune my amps even when starting from the initial recommended setting. Oh yeah, and just a few basics on electrical wave forms so when a reader encounters a fancy TIG machine with 9,000 switches and knobs he'll at least be familiar with the terminology used in the labels. I don't know how you'd pull this off, exactly, but I believe it would be best to get away from other welding books that heap on lots and lots of theory before getting to any actual welding. It would be better to cover just enough to get started, then have practice and additional theory in parallel. Less boredom that way.

Reply to
B.B.

I"m back - 40th year from school - got to see the old guys!

How about metal prep. So many times the welding is just done on this chunk... No prep info - e.g. use SS on AL or don't use xxx sanding disk on YYY... Does it matter on surface 'grain' that is ruffed up on a fine weld (TIG mostly..)

How to test for a bad weld.

Martin

Reply to
lionslair at consolidated dot

Ernie

Thanks for good detailed stuff like the "pencil and washer" exercise for training your hand and arm to do TIG welding.

When I have done welding training I have found "context information" useful. Not only see how you weld but also understand why you do it like this and what the welding system does to make that possible.

I've put in a couple of memorable ones in my training to illustrate things which meant something to me. Hope it is helpful in showing at least one "take" on the subject.

Best wishes with book project

Richard Smith

My examples:

Basic stick (Basic SMA)

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Positional welding with Basic (AWS xx15 & xx16) electrodes. In UK in

1970's / 1980's during North Sea oil rush, Basic, low hydrogen rods were used for positional welding (working at all angles and positions) in fabricating oil rig structures. New type of electrode developed. Only about 1 weldor in 50 qualifying in qualifying tests when initially tried in mid 70's with existing Basic electrodes. Problem. Studied by Phillips Petroleum. Came up with a low-slag welding rod. Weldor could see what they were doing and slag not filling the joint unmanageably. Held up example rod to view. A visibly thin welding rod for its core (wire) diameter. Now capable weldors could pass qualification. Rod now named "Filarc" because sold up by original Phillips Petroleum but name invokes its origin and acceptable to all. Then learned uphill stringer V-butt. Stringer because you are always looking for high properties when you go donw this route of using Basics...

So there you have it - a basket of information - not only how (the technique) but also why - and from where have we come (high-deposition low-hydrogen rods for downhanding but useless for site fabrication where do want Basic's low hydrogen and high strength and toughness but certain to be positionally welding. It's a lot of image of what you are about. When you are working away, you understand a lot of what you are trying to achieve.

Cellulosic stick (Cellulosic SMA)

---------------------------------

Can explain about the pipelaying tradition. The Alaska pipeline and all that. That cellulosics (seem to have?) come out of "shipyard electrodes" of the 1920's(?) where wrapped iron wire in thread of old rope and clay and got reasonable weld properties. Explain how high hydrogen for penetration and therefore good root penetration go together with very little slag, also making for root running through very little slag obscuring the root and quick solidification with not being under and insulating slag blanket. So it all fits together as this root-running electrode. Then go into techniques. But now clearly relating what you are learning to what the welding system inherently makes available to you (it isn't just an accident - it's a design).

Reply to
richard.smith.met

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