need help asap

admin

I have a very important job which includes welding bungs into 4" round tubing.  We have been having great difficulty keeping the customer happy with a continous weld beed.  I feel they are asking for a robotic weld due to the small size of weld bungs and because of up and down hills welds that seem to be unavoidable in this application.  Since the customer is always first, I am striving to find a fix for this situation.  This project is moving very fast and we have found ourselves falling behind.  M experiecend welder haven't come up with and sure fixes.  So far we have been mig welding the couplings.  I am thinking this may need to be tig welded?  Carbon steel weld bungs and aluminized tubing.
Reply:Try a "turntable" positioner yet?----------------------John
Reply:yeah are you turning this round tubing as your welding? Such as welding a run stopping and turning the piece a bit more for another run? if so you need to get an automated rotary postioner or have someone with a steady hand turn the piece as you weld it.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:just tig weld it. if your customer is being picky about weld quality that seems like the quickest solution. personaly if he wants good looking welds he needs to ditch the aluminized tubing but oh well. i once had a job where they made me mig weld 1/2 NPT fittings into a carbon steel shell. i would always tig them because it looked way better but the QC made me stop cause nobody else could do it. he then told me that it was better for them to all look like crap than for me to make everyone else look bad or lazy.sometimes the customer is wrong
Reply:Originally Posted by quasi...sometimes the customer is wrong
Reply:Pulsed Spray?Faster, smooooother, David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I like pulsed spray MIG, but... I would TIG that.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:turn table it is.  I have one coming.  We have also, switched to using our miller 140.  I believe you're right about the aluminized tubing.  Thanks for the info!
Reply:How thick are the bungs and how thick is the tubing?Yer gonna LOVE that turntable.David Real world weldin.  When I grow up I want to be a tig weldor.