3.5 Hrs Later..

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Had 3 dozen hubs to weld to round plates this A.M.Started @ 8:30 finished @ 12:00..Plates are 3/8" thick 12" diameter..Hubs are 4.5"dia 2" thick..These are heads that are for a bunch of rollers that we are making..All done in 1 pass..300 Amps..3/32" Red..1/16" 70S-2 filler..Positioner in use..I get all the fun jobs.....zap!Last edited by zapster; 10-12-2010 at 04:30 PM.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:MAN! Zap I wish I could tig that good. I have never had a use for tig untill recently and would love to lay a bead like that. Very nice.
Reply:hehe, Zap...you get all the fun jobs --Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Very nice work........   I was thinking of doing something like that..........But it takes me two hours to watch 60 min...................
Reply:here's a question for you Zap.  What's the feasibility of welding a 1"x2.5"x3" 1018 cold rolled block of steel to a 1/4"x4"x4" plate of 1018 cold rolled using 1/8" 2% thoriated with an air cooled torch at 200amps max (with foot pedal)?--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Originally Posted by wintermutehere's a question for you Zap.  What's the feasibility of welding a 1"x2.5"x3" 1018 cold rolled block of steel to a 1/4"x4"x4" plate of 1018 cold rolled using 1/8" 2% thoriated with an air cooled torch at 200amps max (with foot pedal)?--Wintermute
Reply:Damn...just what I thought   Now I'll have to get a 300amp water cooled torch and a water cooler for it Thanks for the input Zap --Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:ZAP nice work like to ask ? did you have on a turn table or did you move around . Thank's for Reply
Reply:Originally Posted by jreynoldsweldingMAN! Zap I wish I could tig that good. I have never had a use for tig untill recently and would love to lay a bead like that. Very nice.
Reply:Originally Posted by bigduckZAP nice work like to ask ? did you have on a turn table or did you move around . Thank's for Reply
Reply:Thank's again.
Reply:by the size of them dimes i'm  surprised you didnt use 3/32 filler  ..would that have cooled the puddle too much? you must have been feeding the filler like no  tomorrow ..was the  compete weld more than one 3 footer of filler ? how deep into the pedal were you ?
Reply:Originally Posted by weldbeadby the size of them dimes i'm  surprised you didnt use 3/32 filler  ..would that have cooled the puddle too much? you must have been feeding the filler like no  tomorrow ..was the  compete weld more than one 3 footer of filler ? how deep into the pedal were you ?
Reply:I have enough trouble repositioning the wire to keep going when it gets short. Doing that and then grabing another piece... Nice work..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by zapsterIf you ever get the chance to come up this way..(Mass.)Give me a shout!I'd be more than happy to give ya a lesson for a few hrs......zap!
Reply:great work and congad on your 10,000 +  post
Reply:Originally Posted by zapsterFull throttle at the start then 3/4 of the way down..(I figure around 300 amps..The machine was on hi range...knob at 7) and just make sure you have another piece of filler you can grab without "Looking" so you can keep going without stopping..I used a piece and a half in each weld..86 dips in each..(I count them because I'M board..)Yup 3/32 would have taken to long to melt so you go smaller for better penetration.....zap!
Reply:Well, that's beautiful.
Reply:Hey Zap,Nice job..... YUP, you do get all the nice ones. I'm sure your boss is quite pleased with the profit margin with a job like that..... that's why you are still working everyday. I keep trying to project to everyone that profit is what keeps you working. You did good.To jreynolds: Quit wishing you could TIG that good. It is not hard...... SEAT TIME!  TIG, to many, is the artform of welding. It is done because of the aesthetics & the strength of the weld. All the classic/show car accesories I make w/al.d/plate is TIG & are expensive. The production runs of other d/plate aluminum crafts I make are with MIG because of the lower cost & profit margin & keep the prices reasonable. Zap "made you an offer you can't refuse"....take him up on it.  Here's what to do: Look into the mirror & ask the person you see: "How bad do you want it?"  Then answer......DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:Thanks everyoneTake into consideration Breakfast break @9..Shi++er shortly after...Keeping the lathe running with these stainless shafts that are 80"long and need 1/2" taken off with these stringy  chips that build up...Yeah what a fun time.....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:SHOW-OFF!Very nice work. I have not had much call to be able to tig until recently either, so I'm doing the learning curve too. I love seeing work like that. It gives me hope. StephenMillermatic 251Miller Syncrowave 200Miller 30A SpoolgunHypertherm Powermax 30Etc., etc., etc.............Cancer Sucks!
Reply:Looks good from here, 5.8 mins apiece average? I'd have to weld 50 or so just to get my rhythm down.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:Originally Posted by castweldLooks good from here, 5.8 mins apiece average? I'd have to weld 50 or so just to get my rhythm down.Peter
Reply:That looks like fun, wish I could try a setup like thatkidtigger24  They think I’m crazy, but I know better. It is not I who am crazy. It is I who am MAD!
Reply:Originally Posted by kidtigger24That looks like fun, wish I could try a setup like thatkidtigger24Looks great.300 amps on 3/32 tungsten? What shielding gas are you using? A mix?UA Local 598
Reply:Originally Posted by wintermuteDamn...just what I thought   Now I'll have to get a 300amp water cooled torch and a water cooler for it Thanks for the input Zap --Wintermute
Reply:Your welds are truelly amazing. I only have one question why tig? I mean for a small production run like that it seams that mig would be alot quicker and more profitable. I'm sure there is a really good reason I'm just curious what it is. And again those are amazing welds.
Reply:Originally Posted by Mega Arc 5040DDYour welds are truelly amazing. I only have one question why tig? I mean for a small production run like that it seams that mig would be alot quicker and more profitable. I'm sure there is a really good reason I'm just curious what it is. And again those are amazing welds.
Reply:Originally Posted by WHughesLooks great.300 amps on 3/32 tungsten? What shielding gas are you using? A mix?
Reply:Fair bit of work there zap, each looks as good as the last.There are shops that actually track that 2nd op time and bill at 1/2 price, the the main operation is full shop rate. One in Peoria has a differential in the contract and the men make out their own paperwork each day (hours, billable hours, paid hours, etc). There are a few kicking down some serious dough without a lot of overtime.I understand the looking for somethhing to do on a long machining operation... You can only polish your tools so much, same with preparing the next part.I think the worst is when you're hogging something and have to stay close to the handles, forever..Matt
Reply:Hey Zap,Where those hubs recessed into the disks or were they just sitting flush on top of them?  -Just curious because I have to make a similar piece (but only a little smaller).Ray
Reply:Originally Posted by Ray CHey Zap,Where those hubs recessed into the disks or were they just sitting flush on top of them?  -Just curious because I have to make a similar piece (but only a little smaller).Ray
Reply:You've inspired me to give that type of weld a try or two. I'm using my little size 9 torch at about it's max of 125 amps. The material is 1/4 plate and some 3"  3/8" wall tubing scraps. Attached Images
Reply:Nice welds, and all that, but I'm thinkin 3/16 7024 and what, about half the time?...
Reply:true, but no spatter with TIG!
Reply:not much with jet rod either, and the time saved would allow you to scrape what little there was off with a file...and still make money---
Reply:hey nice welds, but why wouldnt you run dual shield or gmaw sprayon something like that ?   prob cust. request ?
Reply:I can't answer for zapster except to say he did all 36 of his pieces in just 3.5 hours, so I'm not sure how much time anyone could save on that with an alternative method. On top of that the result is near perfection with no clean up (to the welds) required.For my own welds, I'm just a beginner at tig, so it is just practice.  Saving time isn't critical at this point, in fact, I need to spend more time at it.
Reply:Originally Posted by nevadanickhey nice welds, but why wouldnt you run dual shield or gmaw sprayon something like that ?   prob cust. request ?
Reply:wow.  that's some seriously thick material.  How much penetration do you recon you got into the 2" hub?  for us mere mortals, if i were doing this, I should be able to get penetration through the 3/8, but I'd only be able to get maybe 1/4" penetration into the 1/2 hub.sorry to be so confusing, here's where I'm coming from.  say i'm welding this: 3/8" hub (instead of 2") into a 3/8" plate, in the same configuration as your hub roller, I shoot for 90% to total penetration.  But your hub is 2" thick!!  how much penetration into the 2" hub, in this case, is considered acceptable?  was any of the plate and/or hub preheated?inquiring mind wants to know, thanks in advance.
Reply:Originally Posted by oxy moronwow.  that's some seriously thick material.  How much penetration do you recon you got into the 2" hub?  for us mere mortals, if i were doing this, I should be able to get penetration through the 3/8, but I'd only be able to get maybe 1/4" penetration into the 1/2 hub.sorry to be so confusing, here's where I'm coming from.  say i'm welding this: 3/8" hub (instead of 2") into a 3/8" plate, in the same configuration as your hub roller, I shoot for 90% to total penetration.  But your hub is 2" thick!!  how much penetration into the 2" hub, in this case, is considered acceptable?  was any of the plate and/or hub preheated?inquiring mind wants to know, thanks in advance.
Reply:Originally Posted by oxy moronwow.  that's some seriously thick material.  How much penetration do you recon you got into the 2" hub?  for us mere mortals, if i were doing this, I should be able to get penetration through the 3/8, but I'd only be able to get maybe 1/4" penetration into the 1/2 hub.
Reply:Don't really see what all the fussing is about here fellas...From what Zap has said, BOTH the Plate AND the Hub ride on the shaft... They are BOTH cut for a keyway, but only the hub is drilled for the set screw.There really are no forces acting on these that should be tearing the plate away from the shaft...Once the Old Man is done his Spit Polishing and Shining, they should last 100 years as welded.I like to weld the ever-living CRAP out of things too, but it is NOT neccessary in this case.The weldment has to match the application.As to WHY he uses GTAW(TIG) all the time... It is what he has on hand, and it is what makes the shop MONEY.Denny is right, and Profit is the bottom line.There are lots of things that Zap posts that I would approach differently than he does, but the shop I work in is equipped differently, and the Old Man and I have different skill sets... What "Works" for ME, may not work for him, or vise-versa.I have GTAW (Tig) capability where I work too, but I primarily use GMAW or SMAW, so I would probably go one of those routes first.I am NOT hacking on anyone for the questions on this thread, just trying to get you to realize that for the most part, we all work with what we have on hand, and what we are comfortable with... Sometimes our hands are tied by Code Requirements or Customer Specifications...  Maybe keep this in mind, and cut the guys posting the projects a little slack, because they didn't weld out something the way that you think it should have been done.Last edited by Black Wolf; 10-18-2010 at 12:12 AM.Later,Jason
Reply:Well stated Jason..Are you back home now from vacation on P.E.I.?...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:Yep - Vacation is all over for this year.  5 weeks was TOO LONG anyway - I was pretty bored, and ready to get my welding gear back on.Been back at work since Sept 29th and I am so far behind right now, I think I'm 1st.Just the way I like it... LOTS of Overtime and LOTS of MONEY.Later,Jason
Reply:I know its never polite to dig up old threads, especially for someone that just jined up but....Them pictures brought back horrible, horrible memory's.  Great looking welds btw - some day I might be half that good -Long long ago - I worked for the biggest sprocket and gear outfit in the US of A, any of y'all with heavy industrial experience have probably seen our blue boxes.  With very few exceptions, mostly custom work, every sprocket we made looked just like that at some point.Before I moved up into CNC's I took a turn as a welder - running a water cooled mounted  MIG gun 9.5 hrs a day - making 300-1200 of those a day depending on sizes and set-ups just watching 850 pound rolls of hobart wire vanish.  Of course we were geared for full on production using old converted lathes to hold the work pieces and turn them at exactly the right speed as we welded them. pneumatic rams to hold them together while they were welded,  needleguns mounted on swing arms for slag.One question - we were turning them out say 45-95 seconds depending on hub diameter so that may have played a big role in it but -  usually anytime you weld a hub to a plate like that you wind up with a soup bowl - was that less of a problem TIGing them?
Reply:Zap,Finally got around to welding those shackle mounts.  Seemed to work well enough on 200amps, but...damn that torch got hot.Here's the thread with them done:http://weldingweb.com/vbb/showthread.php?t=47055Thanks --Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:zapster  -  Considering the raw material, and the necessary prep, why TIG ?   OPUS
Reply:Opus, that was covered earlier on in this thread.--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow