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Showing results for tags 'welding how-to'.
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When I bought my new Lincoln 216 welder, I also bought an 11 pound roll of ER-70S-6 wire. I bought a metal gauge and estimated that the project at hand was about 1/4" metal thickness. The chart on the machine called for a "D" setting which is about 4 out of 6 possible settings. (Can't remember the wire feed speed off the top of my head. Seemed to work out okay.) Didn't get much splatter. If there are concerns over the integrity of a weld, how could one strengthen the weld? Would you choose to build up a higher crown with a hotter setting, broaden the base of the weld, etc.? David -
One of the popular HD videos at the magazine website and the magazine's YouTube offerings is a field repair welding job at Moab, Utah during the 2012 Jeep Safari. We were at the "Rose Garden" trail on a typically fun Warn Industries media run. I happened to be riding passenger side in a Jeep TJ Wrangler whose owner was the trail boss and a fellow Warn friend. My role was filming, and the lead vehicle was a good place to ride. About 2/3rds of the way up this rock ledged step trail, I was outside the vehicle filming when the steering tie-rod on the TJ Wrangler snapped. The next angle for the camcorder was to film several guys repairing the tie-rod. Front and center was Larry Nickell of Crawl Magazine fame. Other friends from Mopar contributed a pair of Dollar Store quality open end wrenches to the cause. Larry and the Crawl crew whipped the Ready Welder from their rig, removed the battery from the vehicle and went about welding the two open end wrenches to the tie-rod tube. The repair was essentially a "splint" rather than just butt welding the broken tube ends together. A butt surface weld without beveling would surely fail, a dangerous prospect for a steering linkage safety part like a tie-rod. Here is the video: Caution: Welding steering linkage is not advised under any condition other than to get a vehicle safely off the trail to a point where a proper parts replacement can be made. Welding can deform or remove hardening from parts, leaving softer, lower tensile metal in its wake. This repair shown was clearly an emergency. The vehicle was otherwise blocking the trail and would have needed a new tie-rod. Moab was a long, 20-mile trip away. The rough terrain hike to the main road was at least four miles in blustery weather. See how this trail fix saved that day. Did it hold? I rode back to town as a passenger after this 4x4 had negotiated the rest of the Rose Garden with the repaired tie-rod. It did work! At town, a replacement tie-rod was installed the next day. Share your trail welding experiences! I have another one from the Rubicon Trail and a Wheelers for the Wounded outing—our group's Ready Welder became the tool used to fixed a stranger's Jeep that had lost its steering—the mounting bracket had broken, shearing the steering gear from the frame... Moses -
If you need an overview of welding processes and tips on how to weld, there is already a good block of welding information and instructional material at the magazine website (www.4WDmechanix.com). I just dropped the word "welding" into the magazine's search box and the URLs below came up. Many weldors like the gas welding insights, gas welding is a great foundation for TIG and very useful for light gauge and smaller metal parts where a diffuse heat is advantageous. When time permits, I'd like to do an instructional/tutorial on each type of welding, and make the series available for Vimeo On Demand streaming library rentals. These links below are all free: HD Video: 2011 WFTW Trail Welding Repair In this segment, 4WD volunteer John Cox assists a fellow four-wheeler while on the 2011 WFTW Rubicon Super Event. Equipped with a Ready Welder, auto battery operated flux-core spool welder, John quickly performs a repair that will help the CJ Jeep get back to camp. www.4wdmechanix.com/HD-Video-2011-WFTW-Trail-Welding-Repair.html Gas Welding: Tip Sizes and Cutting Torch Settings These charts cover the gas settings and tip sizes for oxygen-acetylene welding, brazing, cutting and heating processes. Review these data recommendations before performing oxy-acetylene welding, cutting, brazing and heating chores. www.4wdmechanix.com/Gas-Welding-Tip-Sizes-and-Cutting-Torch-Settings.html How-to: Gas Welding Session Two Session Two of the gas welding series covers gas welding equipment set up and safety. Setting up the cylinders, regulators, hoses and gas welding torch gets the process started. www.4wdmechanix.com/How-to-Gas-Welding-Session-Two.html How-to: Gas Welding Session Four 'How-to: Gas Welding Session Four' discusses turning on gas safely and setting pressures for gas welding. Learn to safely open the cylinder valves, set correct pressures and turn the system off. www.4wdmechanix.com/How-to-Gas-Welding-Session-Four.html Gas Welding Metal Restoration Video Moses Ludel shares oxygen-acetylene gas welding techniques used in Jeep restoration work. See this slideshow presentation from the 2011 Midwest Willys Reunion. www.4wdmechanix.com/Gas-Welding-Metal-Restoration-Video.html How-to: Gas Welding Practice Exercises For each welding process, there are practice exercises that help improve your skills. In this section of the 'How-to: Welding Class', you will find practice steps for the gas welding material covered. www.4wdmechanix.com/How-to-Gas-Welding-Practice-Exercises.html How-to: Gas Welding Session Five 'How-to: Gas Welding Session Five' discusses setting pressures, lighting the torch safely and beginning to gas welding. See how-to tack weld with oxygen-acetylene process. www.4wdmechanix.com/How-to-Gas-Welding-Session-Five.html How-to: Gas Welding Session Six 'How-to: Gas Welding Session Six' discusses welding beads and filling metal with the gas welding process. In these two HD videos, see the how-to methods for controlling a liquid puddle and using the right filler metal material to run a bead. www.4wdmechanix.com/How-to-Gas-Welding-Session-Six.html Video: TIG Repair of Large Iron Castings At the 2011 Midwest Willys Reunion, Moses Ludel presented details on TIG welding iron castings. In this video you will discover how GTAW-TIG process restored a large iron axle casting. www.4wdmechanix.com/Video-TIG-Repair-of-Large-Iron-Castings.html How-to: Gas Welding Session One Gas welding is the foundation for all other welding methods. In this opening session, Moses Ludel discusses the equipment needs for oxygen-acetylene welding, brazing and cutting. www.4wdmechanix.com/How-to-Gas-Welding-Session-One.html How-to: Gas Welding Session Three 'How-to: Gas Welding Session Three' discusses the choice of gas welding tips, gas pressures and gauge metal thickness. Learn to save gas and select the right gas pressure and tip size for specific mild steel plate thicknesses. www.4wdmechanix.com/How-to-Gas-Welding-Session-Three.html How-to: Completing the Gas Welding Exercise This HD video session completes the gas welded cube project. The demonstration shows the versatility of oxy-acetylene gas welding and its similarity to other welding processes. www.4wdmechanix.com/How-to-Completing-the-Gas-Welding-Exercise.html How-to: Gas Welding Vertical & Overhead Beads This session includes HD video examples of running a gas welding bead. The demonstration of oxy-acetylene welding processes includes beads formed with and without filler material. www.4wdmechanix.com/How-to-Gas-Welding-Vertical-&-Overhead-Beads.html Gear and Transmission Case Restoration Sometimes a gear or transmission case is damaged and obsolete. In this slideshow, Moses Ludel demonstrates how to TIG repair a gear and broken transmission case. www.4wdmechanix.com/Gear-and-Transmission-Case-Restoration.html How-to: Gas Welding Bead Formation This session includes HD video examples of running a gas welding bead. The demonstration of oxy-acetylene welding processes includes beads formed with and without filler material. www.4wdmechanix.com/How-to-Gas-Welding-Bead-Formation.html How-to: Oxygen-Acetylene Gas Cutting Gas cutting is a traditional process for cutting carbon metals. Today, oxygen-acetylene cutting and plasma cutting are both popular. In this HD video segment, see how a gas cutting torch can quickly cut metal in a real world project. www.4wdmechanix.com/How-to-Oxygen-Acetylene-Gas-Cutting.html How-to: Gas Weld Integrity Test This HD video session demonstrates the strength and integrity of the final welding project. The coupon cube gets tested on a 20-ton press to see how the welds react. www.4wdmechanix.com/How-to-Gas-Weld-Integrity-Test.html HTP Circle Cutting Attachment for Plasma Cutters HTP America offers affordable solutions for welding and plasma cutting. Cutting circles is always a challenge, and HTP America has simplified the process with a new, affordable accessory! www.4wdmechanix.com/HTP-Circle-Cutting-Attachment-for-Plasma-Cutters.html MIG Welding Project: Installing the Pivot King When our rugged, six-year-old tire carrier sagged, the Pivot King square tube pivot axle became the solution. Pivot King provides the optimal foundation for building a carrier from scratch, restoring an older carrier or upgrading your rectangular tubing spare carrier. This makes a practical MIG welding project, too! www.4wdmechanix.com/MIG-Welding-Project-Installing-the-Pivot-King.html Video Review: Cold Fire Extinguishers Four-wheeling, welding and shop environments require safety tools. High on the list is fire suppression equipment. Cold Fire is a new method of fire suppression. 4WD Mechanix Magazine reviews the new products and technology from Cold Fire. www.4wdmechanix.com/Video-Review-Cold-Fire-Extinguishers.html HD Videos: 2011 Wheelers for the Wounded Rubicon Super Event The 2011 Wheelers for the Wounded Rubicon Super Event was an exceptional outing. Three years into the program, the volunteers and vets had a great time on the trail and at camp. In this HD video series, Moses Ludel covers the event weekend. www.4wdmechanix.com/HD-Videos-2011-Wheelers-for-the-Wounded-Rubicon-Super-Event.html HTP America's MicroCut 600 plasma cutter is a workhorse. At 40 amps of power, you can cut up to ½” steel. Small size and just 22 pounds means you can take this powerhouse anywhere. With inverter technology, the MicroCut 600 only needs 30 amps of 220 volt power! www.4wdmechanix.com/HTP-America's-MicroCut-600-Plasma-Cutter.html Welding Safety and Protective Wear Welding is a vital part of 4WD and light truck repairs, upgrades and how-to projects. This HD video session discusses welding safety and protective gear. Make your welding a safe shop practice. Use the right protective gear to prevent burns, cuts and eye injuries. www.4wdmechanix.com/Welding-Safety-and-Protective-Wear.html If you put "HTP" into the search box at www.4WDmechanix.com, you'll discover some quality combination TIG/Stick welders and how they set up. They do make good machines... Let me know your interest level and thoughts around learning to weld by way of an HD video welding tutorial/instructional program. Would the "tuition" or cost of streaming video rentals be acceptable, assuming the cost reflects a quality training program and return on your investment? If these videos could be streamed and viewed on a big screen television would that be useful? What about an internet interactive classroom offering live student feedback and real time discussion? Welding is a hand-to-eye coordination industrial art. Many learn better from the visual and even auditory training level than by reading a textbook, although the science of metallurgy is very important and often covered in text. Each medium has its place. Moses
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When i bought my 1994 Dakota, i noticed that the fan shroud was missing. They had rigged an overflow bottle on the core support. When i tried to put a new fan shroud on it hit the fan, so after some searching, i found that the frame was bent right behind where the core support mounts to the frame, which in turn pushed the radiator and core support back a bit. The reason i didn't notice it at first was because they had also made sure to realign the headlights, as well as replace the grill, so all i noticed was that the bumper was bent in. The bend is in front of where the front suspension mounts to, and after talking to a frame shop and alignment shops, the bend won't affect normal driving, and according to them, it isn't critical that it even be repaired. But i don't like having the overflow bottle mounted with bungee cords and zip ties, plus i have plans to eventually install a tube style bumper with a hidden winch, and with the frame bent like it is, the bumper won't attach properly. The frame shop wants what i consider an extremely large amount of money just to pull the frame back, so, after talking to a couple people, their suggestion is to heat up the frame where the bend is, and straighten it back out. My concern is, would heating up that area of the frame stress the metal to where it would weaken it? Also, is it possible the frame would just bend again over time? I don't want to straighten out the frame, only to put undue stress on the new bumper from the frame trying to bend again. I have attached a pic of where the frame is bent. The black piece in the pic is the bottom of the core support where it meets the frame.
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I posted a topic at the welding and metal fabrication forum on one way to restore a bore in a stamped steel piece: "Weld Mold 26-C 'How-to' Oxy-Acetylene Repair: Restoring a Stretched Bore in Stamped Steel". In that 'how-to', I mention heat treated metals and also refer forum members to one of the magazine's slideshow video presentations. The slideshow discusses a major concern when welding, brazing or silver brazing (hard silver soldering) near heat treated parts. Many automotive parts, especially wear points like gear teeth, shafts, splines, thrust washers and running surfaces, have been heat treated to the depth and hardness required. When we weld near any heat treated alloy metals or forged parts, there is always concern about damaging the heat treatment. Even the use of specialized, hard alloy filler materials (some as high as 140K or more tensile in the weld) will not prevent problems at the nearby heat treated areas. If you raise metal temperature high enough during the welding process, any through- or case-hardening will be lost. This means that the metal will soften and be rendered either unsafe or no longer capable of handling its intended function, especially wear points like splines, gear teeth, shafts or thrusts. It is absolutely certain that adjacent to a metal fusion weld, any heat treatment or case hardening will be lost. If parts like a gear or shaft are heat treated or "case hardened" and need welding, you must first "normalize" the metal. This is similar to annealing, but is intended to simply reduce the hardness in the case area, typically the surface 0.030"-0.040" zone if we're talking about common automotive transmission gears and shafts. A ring-and-pinion gear set, due to the size of the gear, is often much deeper case hardening, and some components, especially hardware and fasteners, even get "through-hardened" as opposed to case hardened. Once normalized, a gear or shaft can be welded with an appropriate filler that matches the base metal material. If the match is correct, the part can be machined before re-heat treatment, then heat treated to the component's original Rockwell hardness (prior to normalizing) and case hardening depth if dealing with a case hardened piece. For selecting niche filler materials on alloys and exotic metals, I turn to Weld Mold Company. One way to know the original hardness is a Rockwell C test before normalizing. Determine the depth of case hardening and adjust the final heat treatment accordingly. In the magazine slideshow video, I show and talk about an 8620 cluster gear repair process. There is much more to say about metal prepping, niche welding filler materials and heat treatment...Looking forward to a dialogue in this subject area, we're just beginning! If you have questions, please share. Moses
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Metallurgy and heat treating are a vital part of metal fusing. It is not simply a good bead or welding technique that assures a safe, quality weld. Filler material must match the base metal. Heat treatment is often involved after the machining and finish of alloy metals. Chemistry is a critical part of metal selection and the choice of welding filler materials used with specific alloys. Metallurgy and heat treatment are not abstract processes for manufacturing only. I have repaired obsolete gears with chipped teeth, where the 8620 base metal has been case hardened to 0.035" or so depth at 56 or higher Rockwell C hardness. To repair such a gear requires "normalizing" first to nullify the heat treatment. I have the heat treating shop "normalize" the piece, then the weld repair is made with a specific filler that will fuse with 8620 completely and also heat treat with the same characteristics as 8620 going through heat treatment. After welding, still in a normalized state, the gear is machinable without destroying the tooling. Once machined correctly, the gear can be returned to the heat treater for re-heat treatment. This will be a carburizing process in this case, again with case depth to 0.030" to 0.040" depth, preferably 0.035", with a finished Rockwell C hardness around 60. Does this sound intriguing? It's simply a part of the process when you repair a heat treated, damaged part. TIG, MIG, stick and oxy-acetylene filler materials from a source like Weld Mold Company assure the chemistry that will not only fuse and match the base metal, but also allow the finished product to be heat treated successfully, with uniform results. For insights and sharing of metallurgy strategies and filler rod choices, join this forum and other welders striving for professional results!—Moses Ludel
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Welding can be a gratifying vocation or a hobby. Some weld for a living, day in and day out, and I taught adult education level students to value this trade for automotive body, chassis, structural, casting, maintenance and repair work careers. In this forum, the community of professionals and hobbyists can come together and discuss the various aspects of welding and brazing: stick (SMAW), oxy-acetylene (gas), MIG (wire feed or GMAW, solid wire and fluxcore), TIG (tungsten electrode or GTAW) and silver brazing (hard, higher temperature soldering with oxy-acetylene). Fusing metal properly is highly gratifying, the matching of a metal's base and filler materials, heating to the correct molten point, and building a strong, penetrating, properly shaped weld. In this forum, expect skilled welders to share insights with newcomers about welding processes, brazing rods and techniques plus other aspects of safe welding and welding equipment. 4WD Mechanix Magazine covers welding and metallurgy in articles and HD video how-to. I look forward to checking in at this forum!—Moses Ludel This is an oxy-acetylene exercise, welding a cube together with a variety of welding positions. Oxy-acetylene is the foundation for all other welding processes and very similar to TIG in principle. Each of these photos are from my welding tutorial classes and the welding related how-to available in my articles and HD videos at 4WD Mechanix Magazine and HD Video Network.
