Globular and Short Circuit transfer with Co2 sheild.

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There are posts about Co2 mag welding from time to time, and I have a part that I use both Glob and Short Circuit when welding. The globular for the high heat in the plug weld, and the Short Arc for a small reinforcement over the top without a lot of penetration. The parts are hot when welding,so please be warned your mileage will vary with these settings!Another vid here, and some process pix. The vid is a cut and paste of the 6 last plug welds and cover passes on forged links that crack at the keyway. It is more about the sound of Co2 globular welding at the 200amp range vs the sound of Co2 short arc at the 100amp range.It's faster for me to just use two machines here when I'm going (I really wish the powermig had dual schedule welding in the software). The first two minutes are almost a real time weld of one part, the the next 4 plug welds and 5 cover passes come rapid fire. Somehow I snipped the last plug weld???I also wanted to show the difference (to me) in sound between what is usually called a "soft" arc (Esab/Lincoln) and a "crisp" or "stiff" arc (Hobart/Miller) with short circuit settings. The Lincoln allows setting inductance do do a pretty good imitation of a tapped Millermatic or resistance/tapped Hobart "of the old days" with a very crisp arc. So the first three cover passes are with a T/A 250 (soft arc) and the last three are with the Lincoln set for a crisp arc. The very last cover is done with everything shut down but the welding machine (last part) so the sound quality is very good.All the globular welds are at the same setting, the last three are done without crater fill to allow less time changing the Lincoln over for the cover pass. All settings are noted in the clip below;[ame]http://www.youtube.com/watch?v=B8sjDJorjyI[/ame]Below are pix of how the parts are prepared for the plug weld, and how I do the vise setup. When I checked to see if the URL was good for the film clip... YOUTUBE suggested a crap ton of "LEARN HOW TO WELD" clips for further viewing... Some pretty odd "how to" clips with a ton of view counts???Thanks for looking!Matt Attached Images
Reply:Continued;Below are pix of the part as welded, and after peening a bit. Attached Images
Reply:Continued again;After grit blasting and some hand work around the keyway.Matt Attached Images
Reply:I'm just glad we run argon at work so I can spray and avoid spatter most of the time.Ranger 250 GXTSmith Gas Axe
Reply:I must be missing something here.Seems to be a very labor intensive, messy way to go about a basic repair.What makes globular transfer desirable vs spray?Seems that those milled recesses could be "filled" with a tig weld with much less potential for voids.  There'd also be a lot less post weld cleanup.Also, that's not what I consider "plug welds".Is there any evidence that this "repair" will hold up in actual usage?  It would seem to me that a redesign of the key itself or how the part is designed may be in order.  I really don't see how you've added much strength to the keyway shoulder.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Originally Posted by MrLeadManI'm just glad we run argon at work so I can spray and avoid spatter most of the time.