Sharpening Tungsten

admin

We have crew of about 40 welders on a job. Pipe mostly. Anyway, we have a 6" bench grinder set up at the tool room for sharpening tungsten. Long story short, they are blowing through grinding wheels out there at a rate of a couple per week.I have supplied every type of wheel I can find, experimenting with different types, etc. Turns out, the green silicone carbibe (as commonly suggested) does last a bit longer, but still wears out in a few days.I was curious if anyone else had a solution to keep from wearing out the wheels. The arbor for the bench grinder is 1/2", and there is NOT, that I can find, a diamond wheel (or better) for that grinder. So, outside of buying a new bench grinder with an 1-1/4" arbor, I'm at a loss.However...after calling my best welder, fyi, he may have summed it up the best. He said "Well, I can make a wheel last a year myself using it every day....OR, I can destroy one wheel with one piece of tungsten myself, if I wanted to."So, more likely the "operators" cough cough, of the bench grinder?? Thanks for any input.
Reply:As you say, the wear on the wheel has a lot to do with the welder.So the welders are all grinding their own tungsten?  I picture 40 guys lined up in the morning waiting for one little bench grinder.  Maybe with this kind of volume it would pay to have a youngster re-sharpen a couple hundred used electrodes every day or so to hand them out first thing in the morning.  This way the "sharpening tech" could probably get more life out of the wheel  as well.
Reply:I do not know if you have every tried it, but thier is a product call Chemsharp that chemically sharpens tungsten.  Your welders can keep a jar at there welding station and sharpen tungsten with out having to leave thier work area, which will save you a ton of $$$.  It leaves the sharpen tungsten very smooth, unlike a grinding wheel, which is great for low currents.   See this link for info and video about use.  http://www.dynaflux.com/pages/productpages/cr600.htmlThe list price per jar is $7.60, but you should pay alot less if you use it on a continually bases for 40 welders.Any LWS should be able to get it for you, if you can not find it, send me a private message and I can help you.OAdoctorwww.regulatortorchrepair.com
Reply:Originally Posted by pulserAs you say, the wear on the wheel has a lot to do with the welder.So the welders are all grinding their own tungsten?  I picture 40 guys lined up in the morning waiting for one little bench grinder.  Maybe with this kind of volume it would pay to have a youngster re-sharpen a couple hundred used electrodes every day or so to hand them out first thing in the morning.  This way the "sharpening tech" could probably get more life out of the wheel  as well.
Reply:Thanks for the input.This job was thrown at us last minute, which might help explain the lack of equipment, etc. But hey, any work is good work.I've debated the tungsten sharpening machine...but decided it would be NO different. The same guys who abuse the bench grinder will abuse the new machine. I like the idea of someone sharpening a bunch of tungsten for a day ahead of time. Might just look into that actually. Or...perhaps the special machine AND a dedicated person using it.I just bought some chem sharp per a request from one of my Foreman. I havent used the stuff, but I threw a bunch of out there, hoping for the best.But you know...I would still think there's a market for a diamond coated grinding wheel for this application. Or something that could better take the abuse of tungsten carbide + welders who dont care/know better.
Reply:We use a diamond grinder. The wheel has lasted for about 5 years now. Take turns sharpening eachothers tungsten everyday maybe? 5x40 = 200. Takes about 45 minutes maybe =P
Reply:Got more info on this "diamond grinder"?
Reply:If you can't find a diamond wheel with a half inch whole have someone make you an adapter for the larger 1-1/4 hole so you can fit it on the grinder.  I made one for mounting I-1/4 to a 5/8 shaft.  Just a thought.
Reply:DP68,Go on e-bay and search for lapidary diamond wheels.I use a 100gr diamond cabbing wheel on a small Delta grinder (1/2" shaft) mounted on the left side.  On the right side I have back to back aluminum platter diamond discs.  The one facing inboard is a 360 gr wheel (does most of the sharpening) and the outboard facing one is a 1200 gr wheel (really fine, leaves a mirror finish).The cabbing wheel is good for rough shaping a new tungsten, but too coarse for sharpening.  Works good for cutting a tungsten in half.  Already have a rough point.The cabbing wheel is about $40 and the finish wheels are about $20 each.I use a makita angle drill to hold/spin the tungstenHere's what I'm talking about: Attached ImagesSyncro 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:HTP has a hand held sharpener, don't know how it would hold up to that type of usage. http://www.htpweld.com/products/tig_.../sharpener.htmHH 187Miller Bluestar1EAHP AlphaTig 200X
Reply:I do the drill thing sometimes.  Works pretty slick.
Reply:Sounds like they are using laying the tungsten on the tool rest and seeing how long it takes to grind it down.  I have used the chem dip but we always ground the tungsten to a point and then polished it off with the chem dip.
Reply:Think this would work? Shaft size is good, not sure the grooves are a bad thing, or perhaps just what we need??http://www.diamondtech.com/products/...01/&1244716636
Reply:Originally Posted by GreyhorseHTP has a hand held sharpener, don't know how it would hold up to that type of usage. http://www.htpweld.com/products/tig_.../sharpener.htm
Reply:I have a sharpie DX grinder.  Its a dremel tool with a diamond wheel.  It has different size guides that can be adjusted for angle and the spot it runs the tungsten on the wheel.  Its the BALLS.  I use 20 to 50 tungsten, then batch sharpen them.  A good investment.  I am only one guy...........Tungsten sharpened on a diamond wheel does weld better and lasts longer (until I dunk it).The bigger model would be worth it for 40 guys.  How many do each weldor go through in a day?I would sure pay a young buck or doe to sharpen them than pay weldors wages.David Last edited by David R; 05-28-2009 at 07:19 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I have the Sharpie grinder too.  I got it at Arc Zone.  It works great for me, but I don't think the little wheel would last very long with a shop of 40 guys using it.  Probly burn out the motor too.  I have been in shops where they used belt or disc sanders for tungsten sharpening.  Maybe something to look into.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op