My keggle build, have questions

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I drilled a hole and got great futile of coupler to keg tank. I spot welded around then did this ugly weld you see. Is the lumpy stuff inside sugaring? I backpurged with argon. It was not black it was silver in color. Sent from my ADR6400L using Tapatalk 2 Attached ImagesMiller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:Fitup not futileSent from my ADR6400L using Tapatalk 2Miller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:You backpurged the entire tank? How long did u wait, How many CFH? how big was your outlet hole? Was the outlet at the top and the argon introduced into the lowest point?If it's got a smooth surface it's probably not sugaring, might just be inconsistent burn through of the keg wall. If it's really rough  close up like concrete or lava rock this it's sugaring.Welding/Fab Pics: www.UtahWeld.com
Reply:Yes, the bung at the top was semi plugged with a glove finger. The back purge was at the bottom. I welded the coupler to the tank with the tank on side, bung up, so to speak. I ran the argon at 40 for a few min, then backed down to 20. I could feel the argon flow out of the bung so I figured it must be good. No the bumps were smooth.Miller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:Originally Posted by [email protected]... I could feel the argon flow out of the bung so I figured it must be good. No the bumps were smooth.
Reply:You can hold a lighter near the flow and you'll see the flame act differently when argon displaces the air.Also 40cfh may be a little high unless you have some sort of diffuse flooding cup on the end of the purge hose. A big open volume like that could be difficult to purge quickly without just stirring up the mixture inside and never pushing all the air out. If possible make a foil tape dam on the backside about the size of a soup can rather than purge the whole thing.Also that weld would be unacceptable in sanitary welding due to the "crack" between the parts on the inside. Bacteria will grow in there and you'd never be able to clean it out.For bungs like this it's best to flare the keg wall out parallel to the bung centerline. This allows a butt weld where full penetration is easily achievable instead of an inside corner weld where it's much, much more difficult.More pics at link in my signature.Last edited by MikeGyver; 09-22-2012 at 08:02 PM.Welding/Fab Pics: www.UtahWeld.com
Reply:Thats not sugaring its just penetration. Its good to go,Syncrowave 350Coolmate 3Millermatic 251Spoolmatic 30A
Reply:EliotmayThank you for your direct questions, and excuse my delay in not answering. Saturday is the busiest day of my work week . . we are going into the cold season . . that aside:I see a lot has happened with your project; you just couldn't keep your finger out of the fan !  As a result of starting too soon, you have marginal results.MikeGyver, thank you for putting pics to words, and in post # 6, from memory, could you generally specify what you did to get your superior result - S/S male bung to bucket. Heat/electrode/filler/prep, and most important, your repositioning of the piece for weld-sweeps.Eliotmay, post # 6, is Door Number 3, view M/G's entire site with an eye towards what you want to do, and your questions can be answered.M/G knows more then what is giving up, put him on the ropes.Opusp.s    Both of you, don't rest easy, there is a non-filler Door Number 4, coming soon, to a forum near you.
Reply:MikeGyver, Thanks for the amazing photo montage! Truely inspiring! Regarding my beer keggle project your comment begs the question... How do I flange the beer keg opening to achieve the butt weld you mentioned? Also, won't there still be a seam on the inside since the bung is thick and the keg is thin?Also what filler did you use in the pic you posted? Can I use ss wire as filler? I got a roll of 1.0mm ss wire at aceIf you can, could you post a pic of the back of some of those tank welds if you still have access to them. Sorry so many questions but I'm doing the real deal keg next weekend so I want to do it right! I'll try the foil tape damMiller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:That weld was entirely too cold. What you see on the backside is the ragged edge where there may be enough heat for full penetration, but it's not where it's supposed to be. Speaking from experience, that's from you using more heat to get the toes to wet in, and not focusing the heat at the joint. The coupler is several times thicker than the wall of the keg... Pump some heat to that part and let it melt the base metal before adding filler..Miller: 200dx, Bobcat 225, Passport, Powermax 45, Milwaukee: Dry Saw, MagDrill, grinders
Reply:JohnR, thank you for your advice ,I tried with this 1 to turn up the amperage and concentrate more on the thicker metal  .now I don't think it's cold but maybe its under cut a little bit what do you think am I making progress Sent from my ADR6400L using Tapatalk 2 Attached ImagesMiller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:I use solar flux on my keggle welds I home brew a bunch of beer and seem to always be making keggles for friends and family. Solar Flux you mix with little acetone to make a paste and spread it on the back side of the weld and presto you get a nice weld and no back purge.Solar Flux website I have a small can i think i will die with 2/3 of it a little goes a long wayhttp://www.solarflux.com/Donnelly Small Engine & WeldingFoley AlabamaLincoln 225 TigLinoln 215 migHypertherm Powermax 65Ellis 1600 sawEllis 6000 belt grinderJD2 Model 4 tubing benderAtlas  12"X54" metal latheLots of large hammers
Reply:Just some advise you may already know Never use any grinding or sanding stuff you have used on steel small particles will embed and rust your stainless. Never overheat stainless it will lose it corrosion resistance, weld a very small section and walk away, use a wet rag to cool it if you are really in a hurry!!!you may want to use couplers and center them so you can attach things inside the keg as well as outside I learned this the hard way after doing a few and wanted stuff inside and no way to do it.Donnelly Small Engine & WeldingFoley AlabamaLincoln 225 TigLinoln 215 migHypertherm Powermax 65Ellis 1600 sawEllis 6000 belt grinderJD2 Model 4 tubing benderAtlas  12"X54" metal latheLots of large hammers
Reply:Worm122, so how long can I work before I have to let it cool? Should I go in quadrants? Seems like.it could take a while. My coupler is 80% out and 20% in, that should work I think. I'll test my practice pieces for rust using vinegar salt etcccSent from my ADR6400L using Tapatalk 2Miller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:I would do quarters or less, remember warpage also you are welding very thick to thin. I found that if I did not center the heat affected my threads sometimes you may want to consider centering the coupling.Donnelly Small Engine & WeldingFoley AlabamaLincoln 225 TigLinoln 215 migHypertherm Powermax 65Ellis 1600 sawEllis 6000 belt grinderJD2 Model 4 tubing benderAtlas  12"X54" metal latheLots of large hammers
Reply:thanks I will center the coupleing, last night I put some of my test samples in some vinegar with salt overnight ,so far I see no rust .do you have any advice on preventing the crack on the inside  from collecting bacteria?  it is too deep in there to weld  the back side Sent from my ADR6400L using Tapatalk 2Miller diversion 165Miller mig 211Hypertherm pm 30Milwaukee 6230 14 inch chop sawMd 45 mag drill (RIP; fell on its head)New MD 45! Thanks to the esposa!Finally got an O/A setup
Reply:Bacteria on the hot side of brewing will not affect you. Post boil below 180 or so is what you meed to worry about so a boil kettle if it does get bacteria it will die in the boil. I have never had a problemDonnelly Small Engine & WeldingFoley AlabamaLincoln 225 TigLinoln 215 migHypertherm Powermax 65Ellis 1600 sawEllis 6000 belt grinderJD2 Model 4 tubing benderAtlas  12"X54" metal latheLots of large hammers