Mortaring Up A Joint

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A little show and tellMostly for folks that haven't done this beforeThis is a butt weld.  1 3/4 round joined to 2 1/4 round. 5/32  7018AC running at 175amps.  No preheat, no post heat.I like to plain ol' bevel the pieces using a torch, then cleaning up the cut with a grinder.  This weld was treated the same as welding two pieces of plate together.  No round 'n round shennanigans.Root pass was with 1/8 7018AC at 135amps.  Nice full penetration with the smaller rod.  Allows you to focus a lot of heat in a narrow area.  All other beads were run with the 5/32 rod.  They allow for higher deposition rates.Pic one.. root passPic two... alternate root pass on other side.  (always alternate sides when laying beads, keeps heat balanced to prevent distortion)Pic three... Nearing the end  First of final 3 passes on this sidePic four..... second pass on this sidePic five.... third pass on this sideRemember these were alternating passes.  Care must be taken to insure that there's proper fusion with each pass.  You're filling a large void, and any porosity, or slag inclusions will make all your work for nothing.  You want one continuous piece of metal.More to follow Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Pic one.... weld profile.  Any other metal deposited is strictly for cosmetic purposes to fill gaps in order to make for a nice surface to grind to a finish.  The end of the piece is then ground in order to allow for passes to fill any voids at the ends of the welds.  Not a biggy, just knock the high points down, then hit it with cover beadsPic two...Clarence guarding the piece as it cools (over one hour to cool to the point where you can touch it)Time consuming if done right.  Pay extra attention to removing ALL slag between passes Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Great how-to, Sam.  the more I hang out around these forums, the more I'm learning ....Supervisor Clarence is doing a good job!
Reply:Do you let Clarence hang around while you are welding?
Reply:i'm sure clarence does what he wants to ;  lolbut we do know he s a camera hog, always wants his pic takenhey someone has to keep an eye on the hired help (farmersamm)
Reply:Good work Sam.  I didn't suppose anyone else did it that way, I've repaired a lot of shafts that exact same way form combines to Amish farm implements and have never had one break yet.Trailblazer 302Hobart Stickmate AC/DCLincoln SP 135 TSmith torchSpoolmatic 30A