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Tractor Talk Discussion Forum

OT 20 hours of welding...

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Author  [Modern View]

03-21-2013 16:14:06

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Just wanted to share what I have been working on the past 3 days at work, it's a custom spreader bar for a local company that makes toilet paper. They are doing a one time lift of an electric motor that weighs in at 16,500lbs and are tight on headroom hence the custom spreader. It's constructed from A516 GR50 PL 3/4" and 1" and is 100% full pen welded. Just the welding took close to 20 1/2 hrs of straight welding and two spools of flux core wire. My arm and hand are wore slap out and I am terribly glad to see it going out the door. :o

20hrs and two spools of wire later...

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jon f mn

03-21-2013 19:20:06

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
Looks like a very interesting job. I've only done a couple of jobs with that kind of welding. The first time I did it without leathers because I had never done any hi amp welding. Well I ended up with second deg. burn through my shirt. Had a perfect tattoo of my shirt, including the holes in the buttons, on my chest. I never made that mistake again.

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03-22-2013 05:33:50

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 Re: OT 20 hours of welding... in reply to jon f mn, 03-21-2013 19:20:06  
Ha -

The price of learning on your own.

Not so obvious to a first timer that you're creating your own little tanning booth when you weld.

I never got a shirt tattoo, mine was more of a basic "farmer tan".

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03-21-2013 18:57:16

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
Welding is only about 10-15% of what I do, but the shop ussually sticks with whatever works, so I don't think it'll be any issues to keep getting Esab. I weld up what we call holder blocks. Ussually boxes made out of 1" thick plate, welded to a 2-3" plate, with a bunch of other stuff inside. They're part of the trim tools we make for trimming castings for various foundries. Some spots are too tight to get in with the mig gun, so then I gotta get out the sticks.

Donovan from Wisconsin

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03-21-2013 18:40:12

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
Awesome, looks great! I love to weld as well. Need to go take my tests and get certified.

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03-21-2013 18:06:57

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
Made in America! :D Nice Work! You should be proud!
This post was edited by Dalet at 18:07:38 03/21/13.

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03-21-2013 17:30:29

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
We're in the process of switching to flux core wire for our 350P at work. We always used .062" metal core, but then we switched vendors and the sales guy came in and gave his reccomendations, one being .045" flux core.
I've burned a few spools of it now and I gotta say I like it! I had to switch back to finish up the last 2 spools of metal core which are almost gone now, and then I can go back to the flux core. Even had the Esab rep come in and give me a little demo. Looks like a good job.

Donovan from Wisconsin

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03-21-2013 18:13:20

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 Re: OT 20 hours of welding... in reply to Don-Wi, 03-21-2013 17:30:29  
Quoting Removed, click Modern View to see

Flux core is awesome for any type of structural welding I can go ahead and save you a bunch of grief and tell you to stay away from anything but Lincoln or ESAB wire, anything else will give you troubles with wormtracking and slag inclusions at the worst possible moment.

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Stick welding

03-21-2013 22:05:15

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 18:13:20  
That might have been a good job for sub-arc? 516 gr. 70 is common boiler plate. Don't hear too much of 516 gr. 50. There are some other good flux-core wires like Tri-Mark and a few others. Some users say Hobart has less spatter than Lincoln. That said, I agree on the worm tracking, slag inclusions and porosity with flux-core. I've done a bunch of flux-core and at times it would weld perfect and then have all kinds of problems for no apparent reason and of course in the hardest places to grind it out!

Be glad you could use flux-core. I've welded thick vessels that had to be done with 1/4" 7018 and preheat. Biggest weld I ever worked on was a 2 1/2" thick repad on a 2 1/2" thick nozzle out the side of a vessel. 100% penetration so in essence 5" thick of weld. What really added to the job was the repad was cut for a 24" nozzle but the nozzle was only 20". Of course the shell was beveled to get full penetration after gouging into the back weld(inside) and once it was filled up had to be ground flat for the repad. Then the repad was beveled to have room to get full penetration and once filled up was ground flat with only a 3/8" fillet weld showing. The outside of the repad required a 3/4" or 1" fillet weld as well if I remember right. It took 2 shifts of 2 welders close to 20 hours to weld that up. It took a long time for it to cool off too.

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03-22-2013 05:28:33

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 Re: OT 20 hours of welding... in reply to Stick welding, 03-21-2013 22:05:15  
We mostly build equipment for local plants and have a contract for building paper mill equipment in our shop but we get heavy stuff every now and again but nothing like what you are talking about. I mostly do the odd jobs and the stuff that needs a certification as I am one of two certified welders in the shop. Most of the time you can find me tig welding intricate parts or doing the stuff that needs to have a more delicate finish.
An example of what we do the most of, this is a guillotine used to cutting waste paper rolls up so they can be repupled. I didn't have much to do with the fabrication on this one but I did get in to the hydraulic plumbing and wiring.

Here's a good example of what I do everyday, this is a nozzle that sprays starch on paper somewhere in the manufacturing process. That nozzle is hollow and has nipples on the top and bottom so they can flow cooling water through it and was tig welded with a argon purge to prevent sugaring. I was responsible for developing the patterns, cutting and forming the steel. All the machine work was done in house by our machine shop.

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03-21-2013 16:52:54

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 Re: OT 20 hours of welding... in reply to aarolar, 03-21-2013 16:14:06  
Back in my younger days I was grinding crankshafts and other machine work. I had to build up a journal which was a steady burn for nine and one half minutes. Looks like you may have exceeded that.

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