little crane repair.

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Crack is on the main pedestal that the ring gear is mounted inside of. It is what ties the crane to the truck. It is a 125 ton capacity set up.. first pic is crack getting gouged out. Then some shots of the location. root.And before anyone blows the call someone qualified to do this. I am and am fallowing the manufactures repair procedure. Attached Images
Reply:couple shots of some fill passes. ran out of light for the cap but will get those in the morning. comments and suggestions.....besides the obvious lay of the caffeine so i will stop shaking so much ... Attached Images
Reply:Beautiful root and fill passes   gotta get us some pics of the total weld complete.--Rama"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:I thought you said little. I'll hate to see your idea of BIG. great looking repair.
Reply:Nice work. What rod are you using?
Reply:As long as you don't break out the 110 volt hf unit I wont tell you to call someone qualified looks goodMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:Thanks for the pics!I second the motion for the details. Size carbon, size rod, amps, welder, etc....."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:ok the specs for this little repair. I used 3/8 carbons at 500 amps to get it ready. Then preheated the weldment to 300.I am using 7018 5/32 at 178 amps. I am using a vantage 500. and set the arcforce to plus 3.then just let it lay in there. Thanks for the comments..
Reply:No grinding after gauging?My name's not Jim....
Reply:I know you said you are following the manufacturers repair specs, but 7108 sounds light to me. If that's what they call for, then all is good. I've got a friend who does nothing but crane repairs, and he keeps nothing in his shop lower than 80XX rod or wire and most are up around 110XX or higher. A lot of what he does in on big cranes however, so that might be part of the reason for his choice in filler stock he keeps on hand. I know the manufacturers specs are very stringent for most of the repair work he does. I know the cert process for his stuff wasn't "simple" when I was practicing to do work for him a few years back. I think each cert was over $600 for all the UT, xray, charpy tests ect. that was needed for each position/ process..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:dsw > you are correct in saying that most repairs are 80XX or better. On this particular crane the 80XX and up used only for boom repairs. I might add this is an older crane was manufactured in 1978 The ring pedestal is not a hi tensile like the more modern rigs. Manufacture states that repairs can be made with a 70XX consumable as long as it has hi ductility and has to have a diffusible hydrogen of less than 8. The 7018 fills that requirement very well. Yes the certs are very expensive to pay for out of pocket. 600 sounds about on par for what I pay very strict testing procedure.Boostinjdm grinding is a good practice after gouging. It is a must if you end up with carbon deposits or copper splatter from the gouger coating. These are easy to see . Part of the testing I have done required you to weld gouge and re weld a sample piece. It was a company I worked for wps.
Reply:That's a beautiful repair. Can't wait to see it finished. I'm not a structural guy, (I'm an art/bumper kind of guy) but it looks great to me.I need to get out my carbon arc and play with it soon. (gotta gouge out some tube to make it look like wood)Offering CNC Plasma cutting and welding projects.Follow me on facebook https://www.facebook.com/nobigdeal.fabSupport those that support WW.
Reply:Nice gouge work i wish i was half that goodNice welds tooBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Killdozerd : thanks . I get lots of gouger time as 90% of all my work is repairs. Not something I can go a day without doing. And I can't stand to try to chase cracks with a grinder.Nobigdeal I would like to see how you make tube look like wood. Sounds cool and I need some gift ideas for the wife. She loves metal art so post up some pics.
Reply:The gouging is impressive! Had the crane ever been repaired before?  Can you keep on repairing the crane or is there a point where you throw out the base and start over?  This is an excellent repair no doubt!  I'm just curious about when you would walk away and say get a new one.
Reply:Originally Posted by specopswelderKilldozerd : thanks . I get lots of gouger time as 90% of all my work is repairs. Not something I can go a day without doing. And I can't stand to try to chase cracks with a grinder.Nobigdeal I would like to see how you make tube look like wood. Sounds cool and I need some gift ideas for the wife. She loves metal art so post up some pics.
Reply:Originally Posted by farmshopAs long as you don't break out the 110 volt hf unit I wont tell you to call someone qualified looks good
Reply:I like your beads.It's a common mistake to try to extend/widen larger rod filler passes.  I made it the first time I welded with 5/32.  Your bead is nice and tight the way it should be."Any day above ground is a good day"http://www.farmersamm.com/
Reply:spec - Nice repair, those jobs are always kind of fun, make the day go by! Any sort of preheat required? as for your certification, the truth is in the pictures its great to see a skilled welder, i like how i didnt open this thread and have the OP asking if their 110v arc welder from canadian tire with 1/16" (generic rods) would be ok to use on the job. and Bootsinjim you can see that it was prepd with what looks like a flap wheel, and or wire wheel, which is pleanty to remove any carbon deposits.Last edited by Pressure_Welder; 10-17-2012 at 09:40 AM.
Reply:Great work, and great fix  cant wait to see it finished.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by Pressure_Welderand Bootsinjim you can see that it was prepd with what looks like a flap wheel, and or wire wheel, which is pleanty to remove any carbon deposits.
Reply:WOW!  Did you only hit that with a wire wheel after gouging?  If so, how do you do that (the gouging)?  I’ve only known two guys that can surgically gouge a crack like that. They both repair mining equipment in  AZ and NM.  What’s with you desert rats.  Just beautiful!!Last edited by OHT; 10-17-2012 at 02:48 PM.
Reply:Dang... pretty welds.
Reply:OHT thanks for the gouger complements  I got good at it as I burn more than fair share of gouging rod. It is one of the tools I cant live without.I did pre and post heat. I used a thermal blanket to control cooling.Here is the finished product . It came out ok considering the shakes from to much coffee and redbull.. Caffeine is the worst for my welding but i love it.. lol Attached Images
Reply:nice, likely 15-16 passes in there?Just a thought about not grinding after CACA. With DCEP, and the corresponding half cycle of alternating current, the current flowcarries ionized carbon atoms from the electrode to the base metal. The base metalquickly absorbs the free carbon particles. Since this absorption is inevitable, usethe air jet to remove all carburized molten metal from the kerf.When the air carbon-arc process is used under improper conditions, carburizedmolten metal may be left on the workpiece surface. Its color is usually a dull grayblack,in contrast to the bright blue of the properly made groove. Inadequate air flowmay leave small pools of carburized metal in the bottom of the groove. Irregularelectrode travel, especially in a manual operation, may cause ripples in the groovewall that trap the carburized metal. Finally, an improper electrode push angle maycause small beads of carburized metal to remain on the groove’s edge.The carburized metal can compromise the workpiece for future welding if it stays onthe cut surface. These effects depend on the amount of carburized metal present,welding process used, type of base metal, and required weld quality. Despitemisconceptions that filler metals put on the surface during welding would absorbsmall pools or beads of carburized metal, working with steel base metals showsthat trace metal with only 1% carbon may stay along the weld interface. Such flawsmay lessen weld strength and toughnessI forgot how to change this.
Reply:Now that's good to knowBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Nice job we build and repair Favco stuff all the time most crane work is 50 ksi material and E70xx for everything to D1.5 bridge code . Mfg has specs on most repair work , if it was welded it can be rewelded . most lacing is 4130 . Manitowoc angle chord is A-514 T-1 they have it custom rolled for them . Is you work going to be mag particle inspected and UT ed ???
Reply:The inspector is going to come and ut it early next week. This rig has to go through the recert  regiment. So there will be more repairs I am sure
Reply:Originally Posted by specopswelderIt came out ok considering the shakes from to much coffee and redbull.. Caffeine is the worst for my welding but i love it.. lol