5/16" fillet

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These come from the machine shop.   Rings are surface ground on one side.  10 per skid.Jig to center The set up. material flows down hill  Skid to positioner to saw horses.  Then piled back on the skid. Attached ImagesLast edited by David R; 12-13-2010 at 07:34 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Just started using photobucket.  Sorry...My BabySettings.  .030 wire 400 ipm.  Pulsed spray 92/8 argon/Co2.  LINCOLN wire.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:FinishedClose up of the welds tomorrow.   2 more skids to go.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Nice work. Glad to see your back posting again dave!!!! Any more cell towers in the future?Last edited by welderShane; 12-13-2010 at 08:37 PM.Ya gotta spend money to make money!
Reply:Been wonderin' where you've been. Good to see you posting again.Who is John Galt?
Reply:Good to see you back here, David!Is there any concern about the plate bowing from this welding?Blackbird
Reply:YES it warps pretty good.   Customer will straighten them in a press.I tried 2 smaller passes or one big one. They warp the same, so its one pass.  Its piece work.  Sitting on a stool....I sent one of the first 10 for inspection before I shipped back a whole skid.  I need some banding.  Putting them back to back they rock.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:You have experience running the .030 wire compared to a .035 in pulsed spray, if so how does it compare?Also, does that machine have a program for .030 or are you running it on a .035 setting?Have we all gone mad?
Reply:welcome backthanks for the pics
Reply:Cool pictures, I like seeing how the pros do it.Gordhttp://gordsgarage.wordpress.com/
Reply:Nice job David and great to see you back here again!"One of the things we have to be thankful for is that we don't get as much government as we pay for." (Charles Kettering)Mitch 180 (NZ)Lincoln SAM-400-220 + ?-400 Fordson Major + 2 x Tractapac Humber 80 + Procut 40 PlasmaMiller Spectrum 375
Reply:Originally Posted by sn0border88You have experience running the .030 wire compared to a .035 in pulsed spray, if so how does it compare?Also, does that machine have a program for .030 or are you running it on a .035 setting?
Reply:Good setup, it'd be tough to keep the part from cupping from the weld. You could prolly tack two plates together, weld a ring, peen lightly, flip, weld a ring, peen and cut apart after cooling completely.All that nonsense makes them harder to handle, but it may be cheaper than press work and they should pay for the extra effort.Matt
Reply:I imagine the plate would cup in all directions, but  would a couple of strong back have helped?  It doesn't matter if the customer likes it and is willing to fix it.  I am only wondering in a hypothetical scenario.I used one machine, it was a lincoln cv-400, that was very picky about the wire.  It only liked lincoln wire.  Everynow and then we would run low on wire and I would try and use another wire and it would act up.  That was on hard wire. It would run esab dual shield like a dream.
Reply:The cupping issue was discussed.  It WAS NOT  in the price of the piece work.  I figured 3 per hour.  I can do 5 if I hustle.   I think preheat would help too, but no way I am going to preheat those for the same price.  The customer can straighten them in a press, its normal to them.Stay tuned for close up of the pics. I am going to post one in the mig like tig thread.  DavidHere ya go,   We tried forehand and back hand Push or pull, how ever you say it.    Forehand always seems to work better with pulsed sprayHere Forehand is on the right and back hand is on the left.  The backhand bead is a little more rounded.  Both had the same amount of undercut, not much.  We did all 40 pieces in a couple days with some rest.DavidLast edited by David R; 12-14-2010 at 05:39 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Lookin' good David.
Reply:looks nice dave!Ya gotta spend money to make money!
Reply:Thank you to everyone.   More projects later.  The shop has been busy.We have snow, so the motorcycles are parked.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Nice work. Welcome back! I can't wait for more bucket threads. Heck, post all you can."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:A smaller wire doesn't always have a lower heat input.If memory serves me well:Code:Volts x Amps = WattsWatts x Welding Time (in seconds) = total heat inputWhile a larger wire does require a higher voltage and amperage, it also allows for a higher deposition rate, which means less welding time.  There is a tipping point in every application where the extra time taken using a smaller wire ends up putting more heat into the part than a larger wire would do.  It may be possible that a larger wire would lower your weld time, and lessen the amount of warp that your customer has to straighten, it's a win-win.  It may also happen that .030 is the sweet spot for productivity in your situation.  Just something to think about.  Since you're not being paid to straighten the parts, and the customer is OK with straightening the parts themselves, I wouldn't change the process unless you can achieve faster weld times and the parts are no worse for warpage than current.  The customer might not be to happy if all of a sudden their parts are twice as bowed as they expect.  Now, I have no pulse experience, but if those were to land on my table at work I'd reach straight for .045 gas shielded flux core.  Just my 2¢.
Reply:Static-XJ     I see your point.  I know from experience the bigger wire goes in deeper.  I can slice 3/8 plate if I use .045 wire and crank it up with pulsed spray.Go ahead and use the Gas shielded flux core, it smokes way too much for me.  Metal core would be good , but it too runs MUCH hotter unless I use pulsed spray.    Bare wire is cheaper.....  This job for 40 plates used about 30 pounds of wire.Its got to be if I even use gas shieldedf lux core  wire , it has to be out side or at least with the overhead door and a window open.Look at the pics,   All I did was clean up with a wire wheel.   NO spatter.Today I have to weld 3/8 pipe couplings to 7/8" flat bar about 3' long and 6" wide.  the .030 wire is perfect for that job too.  I have about 100 to do.To those that asked, the bobcats were bid on by my customer.  IF they get the bid, I should get 2 dozen buckets.   That would be 74 shanks.   I would love it!DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:ok who is the great big phony!!!!http://weldingweb.com/vbb/showthread.php?t=48687same gloves, drill press, welders, baby blue jig , forklift, raw materials on pallets hmmmmm and  similar buildshowever i do not see the "x that marks the top" or the metal straps around the plates, and does not have the finished machined prodject.could go either way but what a crazy coincidence if these are 2 diffrent builds.
Reply:Originally Posted by himsa169ok who is the great big phony!!!!http://weldingweb.com/vbb/showthread.php?t=48687same gloves, drill press, welders, baby blue jig , forklift, raw materials on pallets hmmmmm and  similar buildshowever i do not see the "x that marks the top" or the metal straps around the plates, and does not have the finished machined prodject.could go either way but what a crazy coincidence if these are 2 diffrent builds.
Reply:Originally Posted by DSWGuess you've never had repeat work from a customer before. You know where they liked what you did before and want you to do some more because you did a good job?
Reply:If its been too hard to work out, they are both the same person.David mentioned it in another post a while back.Originally Posted by LarryOIf its been too hard to work out, they are both the same person.David mentioned it in another post a while back.
Reply:Originally Posted by himsa169yea its fairly obvious im just curious why would you want to be 2 diffrent people on the same site. does he have 2 diffrent personalities for each name? i assume no by the posts but that would be funny
Reply:Looks good. The shop I worked at specialized in 3/4" to 6" plate. Rarely went below 3/4". We ran 0.045, .052 and 1/16. From what the welding bureau told us was, the largest weld we were certified for a single pass was 5/16 with .052 or thicker wire. We normally preheated 300 to 700 deg. Celsius. (700 ºC = 1292 ºF).  Induction heaters are great. Lots of fun lol.For those who are wondering what a induction heater is... the machine circulates water throw hoses to keep them cool while microwaves heat the steel. The machines we used were around 30 grand Cdn. (those small cables are for heat sensors for the machine to monitor and cycle the heat)Last edited by oxygen454; 01-13-2011 at 02:05 AM.
Reply:Originally Posted by oxygen454Looks good. The shop I worked at specialized in 3/4" to 6" plate. Rarely went below 3/4". We ran 0.045, .052 and 1/16. From what the welding bureau told us was, the largest weld we were certified for a single pass was 5/16 with .052 or thicker wire. We normally preheated 300 to 700 deg. Celsius. (700 ºC = 1292 ºF).  Induction heaters are great. Lots of fun lol.For those who are wondering what a induction heater is... the machine circulates water throw hoses to keep them cool while microwaves heat the steel. The machines we used were around 30 grand Cdn. (those small cables are for heat sensors for the machine to monitor and cycle the heat)
Reply:MoonRise, thanks for correcting me on that. Its been a while since I used that kind of machine. Yes, magnetic currents. We burnt a hole in one of the hoses one time and it soaked the guy welding beside it. (probably why it got melted)