90 full couplings and a new toy

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I got this job in Friday.  This is part one of a bigger job.  These are ends for heat exchangers.   The rest will come in time.  I ordered the positioner for this job.  I have been watching Ebone for 6 mos and they are selling for almost new price, so I got a new one.  200 lb capacity, face plate and chuck.  Variable speed dial and foot control.  I like it.  200 amp capacity.High speed manually operated air cooled OLD oneNew oneWorm drive adjustment.  Lock is on the other side.Last edited by David R; 03-04-2008 at 07:18 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Now for the job.  I have to weld 90 3/4" full couplings on the 1/2" plates.  If you look at the pics above, you will see I replaced the chuck jaws with the reversed ones that came with the chuck.  The "pilot" is a 3/8" drive 3/4" snap on socket.   It fit the application almost perfectly I had to grind just a teeny bit off the top. All the couplings are not the exact same size.Here are the couplings?  Unions?  I guess they are not nipples, but it sounds cool.I removed the mill scale in bulk as I made my way down the skid of parts.Here we are ready to go.  PULSED SPRAY MIG of course.  First I used .035 wire @ 300 ipm, then went down to .030 wire at the same speed.  98/2 was the gas. Of course these have to be air tight and will be tested.CompleteStart-StopLast edited by David R; 03-04-2008 at 07:31 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Here is 1 hours work.  There are about 30.  The speed picked up a little more after that to about 40 per hour.These are some they sent me to repair.  I did not do these.  The red marks are leaks after testing.This is only the beginning of the job.  More to come as more parts come to me.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:STOP NOW you are welding couplings.
Reply:nice new toy and nice looking welds but those are not pipe nipplesthere are full couplingsChuckASME Pressure Vessel welder
Reply:A few notes.  I welded a couple to the socket.  Had to drive it out with the brass punch you see on the vice.  The .035 was a little too hot.  It burned through the coupling.  I also switched to the .030 wire to get a smaller bead.  I still need a lot of heat for the 1/2" plate.  One or more came out not completely square.  I held my hand  on top when I started welding.  Once the start of the weld cooled I was home free.  I musta screwed up on at least one.  I could see it wasn't square.  I will ask the customer about it.  If needed, I will remove it and do it again.  I check all of them as I repack for spatter and any more screw ups.  Quality control inspection.The chuck key came with a spring on it.  I took it off immediately.  It drove me nutz.  Then all I could think of is my dad yelling at me for leaving the key in his lathe chuck.  I always said its a good place not to loose it.  He is right, if the lathe got turned on.......David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Wielro and Chopper5,I edited the title.  You guys are right.  DavidLast edited by David R; 03-04-2008 at 07:27 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:david you are as bad as me when it comes to looking for reasons to buy new toys...  like i say "you didn't know how much you needed it, till you got it."  talking about tools.
Reply:Originally Posted by tortisdavid you are as bad as me when it comes to looking for reasons to buy new toys...  like i say "you didn't know how much you needed it, till you got it."  talking about tools.
Reply:sweet!!!!!!! I need one of those!!!!!If it's too . get an office jobLincoln wp225g7 Lincoln 250 idealarcFrankenstein O/A set-up Weld-tech  tig set-upLincoln sp 175 plus profax  arc gouger
Reply:In the piping world those are known as collars. I use the same modus operandi when it comes to tools and equipment most of the time. Sometimes it's a case of well I always wanted one and I can afford it so I go ahead and get it because I know sooner or later it will pay for itself. Nice toy and nice welds. I'm gonna have to pass on new toys for awhile. My glasses are shot and anyone who wears them knows how bad that hurts. I still think that since I make my living with my eyes they should be a business expense.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Nice.... !what is the price tag for one?Me!
Reply:yours...Mine...=] hahahahBut yes nice welds, really consistent.
Reply:Originally Posted by welder155yours...Mine...=] hahahahBut yes nice welds, really consistent.
Reply:I think I have positioner envy....
Reply:40 an hour?That wont take long to pay itself off.If you dont mind me asking how much was it?Where do you earth David?A good guess is better than a bad measurement
Reply:Originally Posted by David RThe chuck key came with a spring on it.  I took it off immediately.  It drove me nutz.  Then all I could think of is my dad yelling at me for leaving the key in his lathe chuck.  I always said its a good place not to loose it.  He is right, if the lathe got turned on.......David
Reply:Originally Posted by BikespotI have seen it happen a few times now. No one has gotten hurt yet.
Reply:Welder155   Yours IS bigger than mine.Brett, I live in western NY United States. For those that asked how much it cost, do a search for an atlas 200 lb welding positioner.  I paid a little less than list price, the chuck was extra.  No shipping costs.Old one is for sale or give away to a good home.  Just send a PM.I leave the chuck key in the drill press too.    Its just a bad habit.I thought about the crooked one, I am going to cut it off and put it on straight instead of showing it to the customer.  Just do it right.  This is one of my best welding customers and I would like to keep it that way.I had the positioner between speeds 3 and 4.  I was concerned when I bought it that it would not be slow enough.  The LWS told me it was 2 to 8 or 2 to 10 RPM.  Once I got it, I could see it goes all the way down to zero RPM.  Good thing, bigger parts will need to turn slower that the 1" part I was welding on.The next part of this job, the chuck will come off because they are rectangular boxes.  Last time I tigged them.  If I can pulse spray them, I will be in the $ big time.  Its all piece work.  NO air leaks is #1.Don't see any dimes do ya?David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by Jolly Roger  Snip...I still think that since I make my living with my eyes they should be a business expense.
Reply:so the chuck and hold what diameter? Do those guys have a vendor in Asia?Unit in my fab shop dept:my good hand and team that trust me...A lone welder make art... a village full of welder make Miracles...
Reply:Here is the chuckhttp://www.fastenal.com/web/products...ex?sku=0830475And the unit.  I just searched the web for this.http://www.fastenal.com/web/products...99608512&Nty=0DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RBrett, I live in western NY United States. For those that asked how much it cost, do a search for an atlas 200 lb welding positioner.  I paid a little less than list price, the chuck was extra.  No shipping costs.Old one is for sale or give away to a good home.  Just send a PM.David
Reply:Do yourself a favor and just remove the jaws and you have a flat surface without unbolting the chuck..Mine never comes off.....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:Neat little job.  I actually like these gravy production jobs like that.  Question, why are you running 98/2 vs. 75/25?  Do you feel like the spray has better consistancy for seal than traditional mig?Lots of toys.Its Tig or pulsed spray.  Mig can have leaks at the start stop.  At least when I do them.  The last batch I did with TIG and no postioner.  This was much easier.  Not actually a gravy job, I had to hustle to make over my hourly rate but it was fun.  This is a small part of a bigger job.Pulsed spray has a much more fluid puddle.  I can't make a mig weld look as nice as those above or go as fast.The customer picked them up a few days ago and complimented me on how nice they looked.  Made my day.  Next part of the job comes in 2 weeks.  Its a full week of work or more.  I don't know if I will be able to pulsed spray them or not, some of the plate is 3/16".   DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:David,Pulsed MIG is the way to go on parts like this.  But as you say, compared to TIG, MIG is more prone to leaks at the start/overlap.  It is inherent in the MIG process, even with the hot and fluid pulsed spray process, since the initial arc start is always cold and low penetration, and it is very difficult to burn through the start as you come around and overlap because of the high weld metal build-up at the start.Many models of airbag inflators are pulsed MIG welded.  They are 1/8" thick low alloy steel and designed to hold 4000 psig gas pressure for 15 years.  They are proof tested up to 7000 psig and helium leak tested.  I set up machines for welding these inflators and ran 0.045" E70S-3 at 400 ipm, with 92%Ar/8%C02, 5/8" tip to work distance, 20 degree push angle, 300 amps, 24 volts, and 30 ipm travel speed.  The power supply was a Thermal Arc, Arcmaster 501 with the pulse set at 460 amps peak, 60 amps background, and 2.1 millisec peak time (480 Hz).  These high frequency pulse settings produce the very narrow/concentrated spray arc.  The weld joint was similar in size to your parts, around 1-1/4" diameter.  The machine would do around 130 welds per hour.I found it best to keep the voltage/arc length as low/short as possible, while still high ehough to minimize spatter.  The short arc with some crackle and slight spatter was more controllable and consistent than the higher voltage/hotter, hissing, pure spray arc.What are your weld settings for these welds, wfs, amps, volts, pulse, gas, travel speed, torch angle, stickout, gas type?
Reply:You talk about it cold at startup, in a situation like this, would moderate preheat be order?  I love my fast start benzo torch, sometimes when doing short mig weld I will hit it with the torch and get atleast some heat going.  Obviously not red hot, but 400* anyways.  On aluminum its a God send.Lots of toys.
Reply:Brandon, no time for preheat.  I get a couple of bucks plus each. That includes unloading the truck, grinding the plate, cleaning up the coupling and welding them.  I also have to inspect and repack.  Its good money, but no way could I preheat them.  As long as they don't leak, I am good.  The last batch I tigged.  Took much longer.Pulser, my machine has a built in hot start.  I can't tell you how it works, but when I pull the trigger, it welds different for the first second.  I have to hold the gun real close so I don't get any spatter upon startup.  My customer has asked me a couple of times "Can you make a smaller bead?"  He is used to seeing welds like in the pic of the ones I have to repair.  Small Migged ropey beads.  I don't know how they don't leak more.  That is one reason I switched from .035 to .030 wire.  BUT there is a limit to how low I can turn the amps and still get a good pulsed spray.  Once I get below 200 ipm, I can see little balls of weld instead of atomizing the wire.  It also doesn't stick to the base metal vary well.Back to your specs.  .030 wire 300 ipm I get better fusion with 98/2 than 92/8 because I tried both.  If I turn down the "wave control" which raised background current and slows down frequency, the weld goes on better.  It takes to the metal better.  I don't know how else to explain it.  This would probably be 60 amps background and 400 welding current.   20* push sounds about the same as I use.  I can't tell you the Hz, or pulse time but if  you really want to know, I can check it with the scope.  Travel speed is almost 2 rpm.  Pipe is close to 1", so that would be about 6 ipm.    Stickout is between 1/2 and 3/4".   I can't set volts, the machine does it for me.  When it reads welding amps, it reads average.  It says about 116 amps.  Volts I can't remember today.  I can run another weld and read the machine.  It displays amps and volts for 5 seconds after I weld.I set wire speed on the feeder, then set wire size and type on the machine.  Then I set wire speed on the machine and fine tune it for arc length.  Its simple like me.  A short arc length works best, but if it crackles, I get spatter and have to clean it off.  That is part of the glory of pulsed spray.  Nice pretty welds that need nothing more than hit with a wire brush.  I don't think I could do 30 ipm.  The positioner only goes to 9 rpm which would be almost 30 ipm.  I aint no machine.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thats one good reason to love lincoln, they just weld nice.  At work we have millers with push pull systems rigged for aluminum and one panel that can be moved from machine to machine, for when we need to pulse something, but they always seem to be differnt everytime you pick them up. but our best machine is a lincoln on wheels that we fight over often, you can fine tune it so well.  It was broken down so I gave it some tlc, I spent some time tuneing it the way i like it and had my best day of welding aluminum yet. it does pulse, pulse on pulse, with specific sizes and types of wire. i think its a powermig 300, anyway im a lincoln fan, i get excited and can go on a bit.Nothing Ever Got Done By Quitting, Never Give Up.