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I decided to take on a small project with a cast intake manifold and it is driving me nuts.I am by no means an expert, but I have never ran into issues like this before. Even with other cast parts.Welding the two surfaces together was not bad because they had been machined smooth and just ran a bead around it. My issue is there are quite a few mounting holes that are not needed and I have been trying to fill them with 4043.The parts were hot tanked, brushed, whipped clean, and I am still getting a bunch of junk floating up. I heat it up with the torch to try and get a decent layer to work with, but it still looks like garbage.My biggest issue is there is so much stuff in it, when I dip the filler there is a layer that wants to stick to the rod and come out with it. That, and my arc seems to be all over the place at times.I know there is not a whole lot that can done with cast, but any pointers would be great.Thanks-
Reply:Sounds like you're trying to get down into to deep of to narrow a hole. Plus there's probably still some dirt (oil / grease) stuck in the threads. If it were me I'd run a big enough drill bit down in the holes that it would cut a way all the threads. Plus at times I've found it useful to counter sink the holes some so they're not so narrow at the top. I think what's happening is your arc (and you're cleaning action) is just hitting around the upper top rim of the hole and not really getting further down in there where you really need it to be at the start of welding.As to that crusty looking spot in your picture.... if you take a carbide burr and cut that crusty surface layer off you can probably go back over it and get a good looking weld on it. Some times it takes doing that multiple times until it will weld nice and look good.
Reply:I'd bet you'd have much better luck after running a drill bit or reamer through to remove the threads. Then maybe a countersink as mentioned.My name's not Jim....
Reply:If you are trying to fill a hole, you will likely have to cut it 2-3 times its size, to get the bottom and get proper penetration. If you are just laying a bead over the hole, just work your way aroubd until you fill it up. Being hot tanked you might have residue from that left. Like suggested, some blast the surface with the arc, and use the cleabing action and puddle to float the contamination to the top. Then use a grinder to cut the gunk off and weld away.
Reply:Weld it..Grind it..Weld it..Grind it..Weld it..Grind it..Weld it..Grind it..Repeat as needed.It's the only way....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterWeld it..Grind it..Weld it..Grind it..Weld it..Grind it..Weld it..Grind it..Repeat as needed.It's the only way....zap!
Reply:When it comes to working on a Aluminum casting one of these open toothed, single cut, tungsten carbide, rotary files (burr) in a die grinder is going to be your best friend. Unlike a traditional abrasive grinding wheel, rock or point (which smears the metal) it cuts the metal off clean and doesn't leave any abrasive particles imbedded in the surface. Plus it has the advantage of being able to get down into much more intricate areas to remove metal.
Reply:Cut off an aluminum bolt flush in the hole, just welding the surface then.
Reply:Thanks for all of the advice. I am going to pick up a carbide burr to clean it off and go from there. It makes sense now that since everything bad rises to the top, you then need to clean it off and go again. I will try and remember to update this with my progress.
Reply:Walker has the quick way to fix it. I usually drill the threads out, stick an aluminum plug in slightly below flush, cap-weld it and grind the weld smooth. Takes minutes and it eliminates all the heat in the weld area from welding-grinding-welding-grinding etc.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:Yup... weld, grind off contamination, repeat. eventually it will clean up and you'll have a layer of newly deposited material to do whatever you want with.Welding/Fab Pics: www.UtahWeld.com
Reply:The problem in the pic looks as though it got to hot to me. Like mentioned grind it out and weld again.12v battery, jumper cables, and a 6013.I only have a facebook page. https://www.facebook.com/pages/VPT/244788508917829 |
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发表于 2021-8-31 22:46:38