The shaft

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I just got the go ahead for a job today and the dropped off this shaft which will be welded into a cart.  It was a good piece of material until it was left in storage for too long and rusted up.  Any guesses as to what it is for? Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:No idea but thats pretty cool."...My pappy was a pistol I'm a son of a gun...""...God is great, beer is good, and people are crazy..."
Reply:It's a shaft that closes the screen-doors on a submarine  Lincoln AC225 & MigPak 140, Lincoln Magnum SpoolGun, Miller Spectrum 375-X Plasma, Syncrowave 200 TIG, Millermatic 252 MIG, Miller Digital Elite, General 7x12" horiz/vert bandsaw, 3' box/pan brake, 20 ton press, milling machine, 12x28 lathe, etc.
Reply:I thought it was from a machine which makes muffer bearings.
Reply:Originally Posted by rlitmanI thought it was from a machine which makes muffer bearings.
Reply:Oh yeah.. I forgot to mention that it cost $182,000 before it got all rustyCommon sense in an uncommon degree is what the world calls wisdom.
Reply:Originally Posted by BrainfarthOh yeah.. I forgot to mention that it cost $182,000 before it got all rusty
Reply:If it cost that much it'd have to belong to the military. Only the government could afford it. Looks like it might go on an Air Force plane.
Reply:And, if it it happens to be part of the compressed air starter system for a fighter jet  I have a piece that goes with it in my garage. If anyone is interested in it I could cut the price in half. Shipping included.
Reply:Something that goes in the brake (or is it break?) system of a Toyota?  A few of my toys !LinuxMintManjaroMiller Roughneck 2E Lincoln WeldPak 100HTP MTS 160 Chicago Electric 80amp Inverter   Victor O/A
Reply:Main shaft for a Helicoptor rotor system is my guessHarold MulderMiller 211 AutosetHTP 201 Invertig with water coolerHardinge Cataract Quick Change Lathe
Reply:Wow, haroldmulder!  You got it.  I forget what kind of heli it is, but Evergreen bought 5 of them from and Sadi's with a bunch of spare parts.  I guess they can transport 19 people at once.  They are using this shaft to to hold up the rotor hub assembly so they can work on them.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Originally Posted by BrainfarthWow, haroldmulder!  You got it.  I forget what kind of heli it is, but Evergreen bought 5 of them from and Sadi's with a bunch of spare parts.  I guess they can transport 19 people at once.  They are using this shaft to to hold up the rotor hub assembly so they can work on them.
Reply:Whats the estimated power output of those engines combined??i'd still like to know what kind of steel that is exactly."...My pappy was a pistol I'm a son of a gun...""...God is great, beer is good, and people are crazy..."
Reply:4050 shaft horsepower eachHarold MulderMiller 211 AutosetHTP 201 Invertig with water coolerHardinge Cataract Quick Change Lathe
Reply:Originally Posted by haroldmulder4050 shaft horsepower each
Reply:Originally Posted by Crawfordholy ****....
Reply:At $182K, I figured it was Obama's back scratcher.
Reply:Originally Posted by SupeAt $182K, I figured it was Obama's back scratcher.
Reply:Originally Posted by viper522Nope, it belonged to a military contractor - that would make it a Bush back scratcher.Or a bush scratcher?  But that sounds dirty...
Reply:So here is the cart before welding and after with the head unit sitting on it.  I went ahead and incorporated the spline cutouts on the gussets for a tight fit.And the heli is called a Bell 214ST. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:You get all the fun jobs......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:That shaft is either thru hardened then case hardened or at leastthru hardened.      Yes, you've got lots of surface area for the welds to grab,but did you employ and pre/post heat, or weld composition methodsto deal with this?Blackbird
Reply:Naw... Even though another customer that came in and commented that it might be up to 15% nickel (from his experience machining for the aerospace industry), I dont think they will abusing their equipment to a point of this fixtures failure.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Hmmm, take $182,000 helicoptor shaft and turn it into a shop cart for a gizmo.  Yeah, that helicoptor shaft was most likely some g-o-o-d steel.  Not just some low carbon or even just mid-carbon steel.  More likely an alloy steel (4xxx series or 'better') and also likely quenched and tempered and then the spline teeth were also likely processed via carburizing or nitriding.  Wih material and process certs all the way back.  Couple hundred pounds of paperwork to go along with the couple hundred pounds of steel shaft.  Hence the $182,000 cost.Let it rust and it just turns into scrap metal though.I probably would have said to cut off the spline sections and just use the 'straight' section of the shaft.  Less mystery metallurgy that way or having to do those fancy cutouts of the gusset plates to go around the splined areas.  Nice cut-outs and fit-up btw.    The cart would have been a couple of inches shorter.  BFD most likely.Glad it all worked out.  Although I think you should have removed some more of the rust from the shaft before welding it all together.  Usually your work that you post shows a little more prep than this one does.And that heavy looking grey gizmo sitting on that pedestal on top of those four kind-of small casters is kind of making me scared.  Because although the shaft is most likely plenty strong in the pure vertical direction for the weight of the grey gizmo, moving the cart or tipping things can cause the STHTF damn quick.  It just doesn't inspire big confidence.  Heck, the shaft/post looks about the size of a grinder post for maybe an 8inch grinder, never mind an 8-10 ft long 1000+ pound (?) funnky gizmo.  Although that helicoptor shaft is most likely a wee bit of a better grade of material than most grinder pedestal posts are made of.  Not related to the welding at all, but the guy in the green shirt needs to pick up the extension cords flopped on the floor.  Trip hazard!  And he probably needs to be wearing work boots too, unless those floppy sneakers happen to be safety-toe versions.  The best laid schemes ... Gang oft agley ...AHHHH, that brings back memories of my mis-spent youth at the helicopter company. The rotor shaft probably has a damage history in the time cards somewhere (dynamic rollover, static rollover?) or possibly failed one of the periodic inspections for an unseen flaw thus rendering it as a $182K paperweight.   Utilizing it as a build up fixture is a decent use for it, as machining the top end splines alone would cost a bunch.  For a bit of history on the 214ST http://www.aviastar.org/helicopters_eng/bell_214st.phpFor those with interest, the S-64 "Skycrane" type certificate is currently held by Ericson http://www.aviastar.org/helicopters_eng/sik_s-64.phpThe S-61 designation is the "Sea King"  http://www.aviastar.org/helicopters_eng/sik_s-61.phpNice job on the fixture!RogerOld, Tired, and GRUMPYSalesman will call, Batteries not included, Assembly is required, and FREE ADVICE IS WORTH EXACTLY WHAT YOU PAY FOR IT!Dial Arc 250HFThunderbolt 225 AC/DCAssorted A/O torches
Reply:so what's the gray gizmo...some kind of steering assembly is my guess
Reply:my guess was the rotor hub, if you read back he says they are going to use it to work on the rotor hubs. thats what would have normally gone on the end of that shaft when it was in normal use. the rotors themselves attach at the ends of the gray rotor hub.
Reply:Hmmm, I was thinking it has the makings to become a great spud gun.  The most expensive spud gun the world has ever seen!!
Reply:Originally Posted by grnxrymnkyso what's the gray gizmo...some kind of steering assembly is my guess
Reply:I personally would be more concerned about the $5 casters the support cart is sitting on, rather than whether the post will support the load.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 Rog02That is the rotor hub.  The large clevis's are the blade clamps where the airfoils are attached, the link with the shop towel wrapped around it is the "lead/lag" link (used to equalize the lift of the blades), the pitch arms (running from the blade clamp back to the center of the assembly) adjust the flight angle of the blade as it rotates.  The large nut the tech has his hand on is called the "J-Nut", so called because if it comes loose you are going to commune with Jesus.  It actually is the only solid attaching point of the "over slung/under pivot" style of rotor hub.A lot of physics at work when that thing is spinning.
Reply:Originally Posted by SundownIIII personally would be more concerned about the $5 casters the support cart is sitting on, rather than whether the post will support the load.