1" structure for testing square tubing

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Heres a structure made out of 1" thick plate...I really don´t have the measurements, if someone wants it I can take them. The purpose of this is to make some flection, elongation, shear and bending test on a new type of square tubing used for transformers. I think I remember that each side is 6" long and has a 5/8" wall. This is for a company here in Mexico. We we´re given the measurements and had to build it. Plates were cut in the waterjet, then beveled at 45º, then run with 6010, then it will get 3 passes with .035 mig wire and C25, using invertecs VP-300PRO. This passes were done with the 6010 at 122 amps. Any comments gladly received...Oh and here´s a video showing us welders. We welded together at oposite sides to prevent distortion. Alternating heat. Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:2........ Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:3........ Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:cheking squareness Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Welders with their guns Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:A 6010 bead Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Looks like you need a new ground clamp!! Keep the pics coming..Its not done yet and I have to go zzzzzzzzI'll check back in the A.M.Smile now!! ...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:What AMPS?   Rod and Wire size?  IPS?  Volts?MORE PICS DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Another 6010 weld...didn´t hold a stick welder for 1.5 years, please don´t be mean :P (don´t remember which were mines too) Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Another one Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:2 welds............ Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:last one for today! Attached ImagesMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Lotta Plate, little weld.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RWhat AMPS?   Rod and Wire size?  IPS?  Volts?MORE PICS David
Reply:Originally Posted by zapsterLooks like you need a new ground clamp!! Keep the pics coming..Its not done yet and I have to go zzzzzzzzI'll check back in the A.M.Smile now!! ...zap!
Reply:it might just be me but I think 122 amps is no were near enough  for 1" plate what size rod eg 3.2 mm 4.0mm? and I'm not a big fan of welding over stick with the mig as there may be some nastys left from the stick welding that can mess up your mig welds  but looks like a fun job  keep the pics coming you said  (don´t remember which were mines too) you have to remember so if you do a bad one you can say the other guy did it  Creative metal Creative metal Facebook
Reply:I am afraid the single long plate is going to pull and end up being cambered with so much welding.  If you were making two then you could clamp back to back with a shim to prebend the long plate.   Also that is one inch plate.  It should be preheated and temp maintained throughout the welding process.  This a half day job to two welders at the most.  .035 wire is WAY too small.  I am pretty sure there will be some head scratching after the thing is welded.  It likely can be straightened using several time consuming tactics.
Reply:Originally Posted by welloit might just be me but I think 122 amps is no were near enough  for 1" plate what size rod eg 3.2 mm 4.0mm? and I'm not a big fan of welding over stick with the mig as there may be some nastys left from the stick welding that can mess up your mig welds  but looks like a fun job  keep the pics coming you said  (don´t remember which were mines too) you have to remember so if you do a bad one you can say the other guy did it
Reply:Originally Posted by lotechmanI am afraid the single long plate is going to pull and end up being cambered with so much welding.  If you were making two then you could clamp back to back with a shim to prebend the long plate.   Also that is one inch plate.  It should be preheated and temp maintained throughout the welding process.  This a half day job to two welders at the most.  .035 wire is WAY too small.  I am pretty sure there will be some head scratching after the thing is welded.  It likely can be straightened using several time consuming tactics.
Reply:I have built a few pieces similar to that before for a friend of mine who was in the tool and die business.  I fabricated the part and then we put it in a shaper and cut the top and bottom back to being perfectly flat.I agree with wello,  I would be curious as to why they would want you to run a 6010, then finish off with wire?  why not just run the entire piece with one or the other.  You will never be able to get into those corners of that piece with a brush or grinder to clean all the slag,  The only option I could see would be to bead blast the seams after all root passes are done, and then follow with the migs.  Just my thoughts  ~JacksonI'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Did anybody consider the capacity of the table.  I would guess you have about 1000lbs on it now and you are going to add more.  Even if the table doesn't collapse, I don't see any gussets for lateral support.  A shift or pull and the table might not stop moving.Looks like fun, be safe.
Reply:Originally Posted by Hammack_WeldingI have built a few pieces similar to that before for a friend of mine who was in the tool and die business.  I fabricated the part and then we put it in a shaper and cut the top and bottom back to being perfectly flat.I agree with wello,  I would be curious as to why they would want you to run a 6010, then finish off with wire?  why not just run the entire piece with one or the other.  You will never be able to get into those corners of that piece with a brush or grinder to clean all the slag,  The only option I could see would be to bead blast the seams after all root passes are done, and then follow with the migs.  Just my thoughts  ~Jackson
Reply:Originally Posted by tapwelderDid anybody consider the capacity of the table.  I would guess you have about 1000lbs on it now and you are going to add more.  Even if the table doesn't collapse, I don't see any gussets for lateral support.  A shift or pull and the table might not stop moving.Looks like fun, be safe.
Reply:Just a little more info, The square tubing will be subjected to a compressive force of 100 tons...And I said it was 6 x 6 x 5/8....It´s 14 x 14 x 5/8....And could upload the video till now, not something extraordinarie but its something...My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:JUST MY OPINION.  Its a nice project, but you are not putting near enough heat into it.  1" plate takes a whole bunch O Heat.  Even with 1/2" fillets on each side, it may not be enough.  Just a guess here, but 1" plate = 3/16 rod, or really big Mig wire.  And a WHOLE bunch of amps with preheat.I quote from the book again, Lincoln handbook for arcwelding.1" plate horizontal weld.  45* bevel both sides to 5/32 Root.  5/32 gap between plates, 3/16" 7018 rod, 240 amps, 5 passes per side.Here is a T weld just like yours.  1" plate, 3/4" weld size. Pass 1 -5 1/4" E7024 375 amps.  this is on one side of the T.Nuter one, same as above, 1/4" 7018, 5 passes 350 amps.Just to show you what the book sez.  Not preaching.  Its your project.DavidReal world weldin.  When I grow up I want to be a tig weldor.Bead blast is probably refering to sand balsting, with a different kind of media. Was it suggested for getting into te corners?_________________Chris
Reply:Looks like a fun project. Is it common to not wear gloves while stick welding?Lincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:Originally Posted by David RJUST MY OPINION.  Its a nice project, but you are not putting near enough heat into it.  1" plate takes a whole bunch O Heat.  Even with 1/2" fillets on each side, it may not be enough.  Just a guess here, but 1" plate = 3/16 rod, or really big Mig wire.  And a WHOLE bunch of amps with preheat.I quote from the book again, Lincoln handbook for arcwelding.1" plate horizontal weld.  45* bevel both sides to 5/32 Root.  5/32 gap between plates, 3/16" 7018 rod, 240 amps, 5 passes per side.Here is a T weld just like yours.  1" plate, 3/4" weld size. Pass 1 -5 1/4" E7024 375 amps.  this is on one side of the T.Nuter one, same as above, 1/4" 7018, 5 passes 350 amps.Just to show you what the book sez.  Not preaching.  Its your project.David
Reply:Originally Posted by lorenzoBead blast is probably refering to sand balsting, with a different kind of media. Was it suggested for getting into te corners?
Reply:Originally Posted by Carl26Looks like a fun project. Is it common to not wear gloves while stick welding?
Reply:Perhaps this could have been a machining project.  Why not screws.  Could be dissembled easily and machined dead level. I realize this is not your project, I'm just throwing that idea out there.
Reply:Well it is a learning process. You're doing great considering the onsite intructions you've been given. If you could possibly slip in a little of the advice the guys are giving you here without hurting any feelings it would be an advantage tho.
Reply:What is the capacity of your elevator...are windows convient....  I have built stuff too large for me to handle or to large to get out my door.  After admiring my work, I discover it is time to get to cutting in order to move.  However I have never dealt with that much 1 inch plate.  Actually, can't remember ever welding 1" plate.What about less welding to miimize distortion--alternating stitch/spot welds?I does look like fun.  Don't have to worry about blowing holes.   At 300 amps would you blows holes in 1" plate be a concern?Last edited by tapwelder; 05-18-2007 at 09:07 AM.
Reply:300 amps?  The most I've ever run a stick at was 185 amps for some 3/16ths 7018.
Reply:you still won't blow thru 1 inch plate with 300 amps....  I weld replaceable feet on ripper's that the farmers use around here and they are 1.25" x 6" flat bar butt jointed.  I run 3/16" Murex 7018MR's at 250-270 amps never blown thru one.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Originally Posted by tapwelderWhat is the capacity of your elevator...are windows convient....  I have built stuff too large for me to handle or to large to get out my door.  After admiring my work, I discover it is time to get to cutting in order to move.  However I have never dealt with that much 1 inch plate.  Actually, can't remember ever welding 1" plate.What about less welding to miimize distortion--alternating stitch/spot welds?I does look like fun.  Don't have to worry about blowing holes.   At 300 amps would you blows holes in 1" plate be a concern?
Reply:Little update...project is on hold until we buy a "i don´t know how you call it" tool. It´s like an end mill style tool which instead of being cilindrical it has a sphere at the end. Maybe someone could help with the name 8SHere we call them turbinas which translated would be "turbine" but, googled it and couldn´t find a pic that shows that´s what I´m talking about.Well that´s it!My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:A reamer perhaps.  What are y'all going to to with the tool?
Reply:Burrs for getting into the corners??http://www.american-carbide.com/Burs/Bur.aspx
Reply:A mill with a spherical shape is a ...Spherical end mill or Ball end mill.Like this http://www.use-enco.com/CGI/INSRIT?P...PARTPG=INLMK32If it is for use in a die grinder, it would not be a milling cutter but a burr.  Like thishttp://www.grainger.com/Grainger/items/1Z410
Reply:YUP!that´s the one...it´s a burr :$ sorry for the incovenience...As soon as we get ours we will start cleaning the 6010 and then MIG it...Thanks for the help!My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Wouldn't a needle scaler work better than a die grinder with a burr??  One like this - http://www.shop.com/op/~Chicago_Pneu...-prod-23162923
Reply:Originally Posted by 76GMC1500300 amps?  The most I've ever run a stick at was 185 amps for some 3/16ths 7018.