|
|
Below are some pics of a aluminum roller that I need to sleeve the journals on..The journals are aluminum so it should be no problem...Right?Study the pics below and see if you can figure out what's going on here..Trust me on this..I would NOT believe this if someone told me about it!I will let you know shortly....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:Ok, why does that look like someone tried to MIG steel over aluminum?
Reply:Whatever it -was-, it's all coming off now!Aluminum buggered onto a steel stub-shaft somehow? And not just a press-fit aluminum sleeve onto a steel shaft, but somehow 'welded' on there sort-off but not really? The best laid schemes ... Gang oft agley ...
Reply:You get all the fun jobs!!!hahahahahahaha!!Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Reminds me of the time someone wanted me to reweld the channel running between the tanks on there truck. I looked and saw a 6011 bead that looked cold and didn't stick. Sure no problem. I start cleaning it up and figure out in short order that the channel was aluminum (it was painted so it wasn't obvious looking at it).Millermatic 252XMT 304'sDynasty 280DXHypertherm PowerMax 1250Miller Trailblazer 302 EFIOptima PulserXR feeder and XR Edge gun and more athttp://members.dslextreme.com/users/waynecook/index.htm
Reply:looks like an aluminum shaft which was welded over with mild steel (er70s?) by someone who probably should be flogged with a cane just for getting near a welder --Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:Originally Posted by rlitmanOk, why does that look like someone tried to MIG steel over aluminum?
Reply:Originally Posted by wintermutelooks like an aluminum shaft which was welded over with mild steel (er70s?) by someone who probably should be flogged with a cane just for getting near a welder --Wintermute
Reply:would the hardness be due to aluminum oxides possibly produced during the welding process? just curious...also, since this is my first reply on this forum, am i required to list all my welders? still curious.
Reply:Yeah and post pics of your wife. Ha!, No just kidding Originally Posted by wardog since this is my first reply on this forum, am i required to list all my welders? still curious.
Reply:Originally Posted by davo727Yeah and post pics of your wife. Ha!, No just kidding
Reply:Ya thats true Jim Originally Posted by BoostinjdmCareful what you wish for. Not every woman is a beauty queen.
Reply:You must have a wacko magnet buried beneath your work area, maybe an old Indian burial ground or some other thing of that nature.....cause damn the funky stuff seems to ask for you by name. But hey, a challenge can be a good thing or it can be a pain in the ***....either way, I'll bet your solution kicks ***.Mike
Reply:Oh, I wonder how bad the galvanic corrosion is after a crazy mixing of media such as this. Seems like when something like that would fail it might do so violently. I recently had a locking lug nut key for my lexus shear itself. For one it was a stupid , weak design and two , it was a steel lug torqued into an aluminum hole, subject to heat due to braking. I resorted to a cam type stud remover and before the corroded layer would break free the tool's cam exploded.If they just woulda put a steel sleeve or cup between the lugnut and the rim........relentless pursuit of perfection my ***. They need a more accurate slogan. And that folks is my rant.......MLM
Reply:Originally Posted by davo727Yeah and post pics of your wife. Ha!, No just kidding
Reply:Originally Posted by zapsterSo Monday I will just cut the end off..Drill..Bore and insert a new ALUMINUM piece to get this done..No welding required....zap!
Reply:Originally Posted by VPTAre you going to press in a new shaft or thread it in?
Reply:Oh ok, I am familiar with the process, it is how supercharger internals are assembled. One part in the oven and the other in the freezer, over and over again until everything is together.
Reply:When I was in the navy we called the reverse of that process "hot wrenching". I had not thought of doing the reverse in assembly of parts , but now that you mention this it makes much more sense than doing a simple press fit.MLM
Reply:I guess this pretty much goes to number #1 in my hall of fame...I was involved with a mining truck mfg in the late 70's, who had someone in engineering decide it would be better to weld bronze over a suspension tube to improve on the traditional approach of using split bearing material in gooves cut into the tube & changing the bearing pieces after a specified number of machine hours.The idea was to still use the composite bearings but the outside of the tube would be bronze not AISI 8630 so no steel against steel could happen in a bearing failure.Good idea, given the price of suspension tubes & housing were in the 5 figure range each to the customer.Something went wrong with instructions from the mig wire supplier and the material was put on with a spray process on a miller gantry and a big Delta Weld.The tough bronze got together with the 8630 & pulled up blobs of 8630 and direct hardened them. Before the grooves were cut for split bearings & seal rings and the OD ground $11,000+ dollars was spent on Manchester grooving inserts and $1,500+ dollars on silicon carbide grinding wheels. There were 24 tubes in the shop and took 6 men three weeks to complete a job that normally took 4 hrs per tube...Everybody in the shop was bummed over that mess.Matt
Reply:Originally Posted by BoostinjdmCareful what you wish for. Not every woman is a beauty queen.
Reply:Here is the way we deal with impossible material..Pic 1 Cut off tool at work..Pic 2 Drilled and bored..Pic 3 New end for roller.. .005 oversize than the bore..Pic 4 Heat roller and insert new end..(No welding required..)Pic 5 DONE!!! Get it out of here!!!I 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:Originally Posted by zapsterHere is the way we deal with impossible material..Pic 3 New end for roller.. .005 oversize than the bore..Pic 4 Heat roller and insert new end..(No welding required..)...zap!
Reply:Originally Posted by zipzitZap, many thanks for showing off your craftsmanship. Your work inspires me.Does the ID/OD interference thing work that well because its aluminum? (I would have thought you would need locktite or other filler..) What happens when you heat one side, cool the other, and only are able to get the thing half way pushed home? Do you drill it out, and start all over again with a new insert? Again, many thanks for your posting.
Reply:Originally Posted by zapsterThis works with any metal..Believe it or not there are grades of cast iron that will actually shrink when heated..I found that out the hard way one day..Trick is to set your dial calipers to the bore and lock it in place..Heat and keep checking until the calipers go inside with room to spare and as fast as you can insert the new piece...It only takes about 30 seconds for the piece to cool down enough so you don't have to hold it in..I have not got one stuck half way in years..After it is in place let it cool until you can touch it by hand with no ill effects then have at it!If you can finish machine any piece heat shrunk in without it spinning around on ya you are good to go.If you plan on doing this to something that gets real hot during use then welding must be done but in this case it's just an idler roller.....zap!Unfortunately you are going to see more and more of this kind of thing considering the lack of skills and training of young people.The MIG welding process is also improperly used by many beginning welders.I saw a gate being constructed at a True Value hardware store by a young and older man the other day. One was wearing sandals and shorts welding with one hand.110V wire feed welding 3/8 thick plate to pipe. Part of it already broke,(fell apart).Hope no one gets hurt.I already told the store it will all fail.I know you some of you Republicans may not like it, but we need some regulations about businesses hiring welders that have no qualifications, and doing work that involves the public safety.Or enforce existing laws.Last edited by Donald Branscom; 05-25-2011 at 03:32 PM.AWS certified welding inspectorAWS certified welder |
|
发表于 2021-8-31 23:37:38