How should this be welded

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I am building some traction bars for my truck I am using 2"od x .250" wall thickness DOM tubing and I machined these special threaded ends that need to be welded onto the ends of the DOM my problem is I don't know what kind of material I used all I do know is that it is a cold roll and it was painted white on the end . All I have to weld with is a SP 250 lincoln welder . I do have a friend that could tig weld it but I would like to weld it myself . can someone chime in here and help me out .
Reply:if they are not the same materials....find out what they are. it would be easier to give you a filler metal compatiable for joining two different materials.only thing worse than an ugly woman is an ugly weld
Reply:Originally Posted by El_Lloydeoif they are not the same materials....find out what they are. it would be easier to give you a filler metal compatiable for joining two different materials.
Reply:call the company u got it from and ask....do a grind test on it and look at the sparks it throws. id call the company though to be sure.only thing worse than an ugly woman is an ugly weld
Reply:Originally Posted by El_Lloydeocall the company u got it from and ask....do a grind test on it and look at the sparks it throws. id call the company though to be sure.
Reply:different metals throw different types of sparks when they are ground. just a way to try to identify a metal. Not all metals will throw sparks though. id call....only thing worse than an ugly woman is an ugly weld
Reply:You must have a general idea of whether it's mild steel vs high-carbon or tool steel from the way it behaved when machined.  You could send the chips in to be analyzed. Can you find another similar piece and test it for hardening ability or its reaction to welding?
Reply:Originally Posted by Oldiron2You must have a general idea of whether it's mild steel vs high-carbon or tool steel from the way it behaved when machined.  You could send the chips in to be analyzed. Can you find another similar piece and test it for hardening ability or its reaction to welding?
Reply:Sorry, but with those kinds of questions I think you should get someone more experienced to weld them for you.Just my $0.02Gordie -- "I believe you understand what you think I said, but I'm not sure you realize that what you heard is not what I meant."
Reply:I don't know that welder; is it just set up for stick? If I were new to welding, I'd make up another turned-down piece without the rest of the machining, and a short section of tubing to fit it into, then weld it as you think best, next do some destructive tests to see if it holds up or shows any crystallization, stress cracks, inclusions, or other defects, and then I'd let my skilled friend weld the actual part I needed.You would probably do fine, but if it came apart at the wrong time, it's too late to change your mind.
Reply:Originally Posted by NiteskySorry, but with those kinds of questions I think you should get someone more experienced to weld them for you.Just my $0.02
Reply:Originally Posted by Oldiron2I don't know that welder; is it just set up for stick? If I were new to welding, I'd make up another turned-down piece without the rest of the machining, and a short section of tubing to fit it into, then weld it as you think best, next do some destructive tests to see if it holds up or shows any crystallization, stress cracks, inclusions, or other defects, and then I'd let my skilled friend weld the actual part I needed.You would probably do fine, but if it came apart at the wrong time, it's too late to change your mind.
Reply:Originally Posted by dieseldorkI have been welding for over 20 years but I have always new what kind of material I was welding this time I don't and was just looking for some input .
Reply:Originally Posted by NiteskyScuse me but you don't know what a grind test is and you don't know what the material you got from your rack is so what am I to think?  20 years EH?  Weld away then.Surely you don't think one of us knows what you used for material do you?
Reply:Originally Posted by dieseldorkyadda yadda yadda WHAT EVER
Reply:OK, so what kind of material does through those racks?  DO you deal in mostly steel, exotic steels, tool steels, stainless, cromoly?  What are the possibilities?  You should have a pretty good idea what types of steel it could possibly be, or try welding a scrap piece and see what it does.I might not know exactly what alloy steels come through our shop, but i know they are all readily weldable without special treatments or procedures.  We dont use tool steel, high carbon, cromoly ect.Have we all gone mad?
Reply:Originally Posted by sn0border88OK, so what kind of material does through those racks?  DO you deal in mostly steel, exotic steels, tool steels, stainless, cromoly?  What are the possibilities?  You should have a pretty good idea what types of steel it could possibly be, or try welding a scrap piece and see what it does.I might not know exactly what alloy steels come through our shop, but i know they are all readily weldable without special treatments or procedures.  We dont use tool steel, high carbon, cromoly ect.
Reply:If it's like the cold drawn tubing I buy for making hinges, it's probably 1022(if I remember the no. right).  It welds just fine with 6011, 6013, and 7018.  I'd go with the 7018.  From what I understand, 7018 is a good choice for dissimilar metals(low and med. carbon).Looks like the weld is just to hold it stationary on the plug you machined to go inside the tubing anyhow.  Is it under stress, or compression, or both?If you're worried, bevel the tubing so's you have full penetration down to the machined plug part.Anyhow, that's what I'd do."Any day above ground is a good day"http://www.farmersamm.com/
Reply:I'm confused.It is threaded into a split coupler with 3 set screws. Why in Gods name does it need to be welded.I don't believe you are going to get enough torque on it to unscrew it 8 or 10 turns.A butterfly without wings, is just an ugly bug
Reply:Why didn't you just thread the tube and use a jam nut???Like doing things the hard way???
Reply:Originally Posted by TSORWhy didn't you just thread the tube and use a jam nut???Like doing things the hard way???
Reply:Originally Posted by makoman1860Actually the way he has it layed out from a threaded attachment point of view is far supperior to a "jam" nut. As far as the material......its anybodys guess. Probably the safest thing to do is use the lease intrusive method of welding. I.E. preheat, use a lower tensile strength ductile filler, and post heat. The details are determined by the mass of the parts. However this is not a "given". Without a way to scan the material, your always going to be guessing, and thats not good on a part like that.
Reply:Dude! smack it with the pointy end of ur chippin hammer. If it makes a divit then weld away. If not you better do some reserch. TIG is going to be stronger so maybe you should let yer buddy do it.Air vantage 500 on the 08' KWharris torchesl25 pro suitcasecomletely restored 1969 SA200 redfaceon my 08' duramaxPIMPN AINT EASY
Reply:Originally Posted by Magnetic MechanicI'm confused.It is threaded into a split coupler with 3 set screws. Why in Gods name does it need to be welded.I don't believe you are going to get enough torque on it to unscrew it 8 or 10 turns.
Reply:Originally Posted by TSORWhy didn't you just thread the tube and use a jam nut???Like doing things the hard way???clean it pre heat weld with t-91 flux core or 7018 cool in a buck of floor dry
Reply:Well I called the 2 steel places that this piesce could of came from and the first one never has carried that size and the second place said that white is their color code for 1018 steel which is releaving to hear because that is a lot easier to weld .I know some of you probably question my 20 plus years of welding but if the only thing you've welded on all this time is square tubing & hot roll you'd understand my question .
Reply:Well that's good news if correct- would have been fun trying to get a good weld if it turned out to be a free maching grade!! Leaving a sharp edge at the end of the slot may well bite you with time, really should be radiused to stop the slot from growing
Reply:Originally Posted by hotrodderWell that's good news if correct- would have been fun trying to get a good weld if it turned out to be a free maching grade!! Leaving a sharp edge at the end of the slot may well bite you with time, really should be radiused to stop the slot from growing
Reply:Dieseldork,Personally, I'd drill a 1/4' hole all the way thru the tubing and plug weld it.  Then run a tig bead all the way around the circumference.I'd be willing to bet the tubing will fail before the welded joint.Easy solution.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 SundownIIIDieseldork,Personally, I'd drill a 1/4' hole all the way thru the tubing and plug weld it.  Then run a tig bead all the way around the circumference.I'd be willing to bet the tubing will fail before the welded joint.Easy solution.
Reply:Most of the DOM 2" dia 1/4" wall tube you will find is ASTM A513 / ASTM A519 grade 1026.Last edited by qaqc; 02-24-2009 at 06:11 PM."Religion is regarded by the common people as true, by the wise as false, and by the rulers as useful." -- Seneca the Younger
Reply:Just have your friend TIG it and use ER70S-2.Unless one part is stainless then use 309L or 309.That rust needs to be cleaned off in the weld zone.Don't let your ego get in the way, TIG it.AWS certified welding inspectorAWS certified welder
Reply:Originally Posted by TSORIf the insert has threads that far into the tube and you plug weld it, you will have to re-tap the insert after it is welded.
Reply:Originally Posted by Donald BranscomJust have your friend TIG it and use ER70S-2.Unless one part is stainless then use 309L or 309.That rust needs to be cleaned off in the weld zone.Don't let your ego get in the way, TIG it.
Reply:Set it on "High"and weld  itEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge