Tig: round stock to thin flat stock

admin

I need help on welding a .250 O.D. stainless round lever to a strip of .060 stainless .625 wide X 8 " long.  I've been practicing, but of course the  S.S.rod heats up slower than the strip causing burn through and warpage.  What kind of amperage should I be using?  I was trying a 3/32 tungsten, should I go smaller? And on top of that, the weld is gray (overheated).  Should I tack opposite sides of the rod's O.D. with filler rod to avoid undercut at the base and then cook around the circumference before it cools down?  Any suggestions are appreciated.  Thanks.
Reply:How is this being oriented?  Like round stock to a flat plate t joint, or round stock laying sideways on the flat stock?
Reply:The SS rod is bent into an L-shape with the short leg (2") positioned vertically and the long leg (6") running parallel to the strip. Sorry the drawing is at work. So, yes it would be a tee joint w/fillet weld.
Reply:Try some 1/16" tungestion ground really sharp..Like the one I stabbed my finger with today.. 1/4" Round to .060 flat..I'd fuse it..80 amps max...Drag the rod to the flat..Start in the middle with "dragged" tacks..Then spot tack the ends..Work back and fourth in 1/2" lengths from the middle out  Try to keep the flat stock clamped down if possible...Go slow..but go fast.. ...zap!...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:I agree, clamp the bejeezus out of that strip.  I would use some .040 filler though if you have some.  Keeps you from having to drywash it, and gives you a bigger puddle to bring down, so less chance of burning the strip away.
Reply:I would use some .040 filler though if you have some. Keeps you from having to drywash it, and gives you a bigger puddle to bring down, so less chance of burning the strip away.
Reply:To clarify, the short leg is vertical and the end against the strip is to be welded.  While the long leg is in the air running the length of the SS strip.