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Old 10-18-2007, 01:55 PM
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Default Anyone ever weld filler rod together?

Did a job yesterday where the finished product consisted of a piece of 3/32" 316 stainless filler rod that was formed and tig welded. I can't say that I have had many jobs where filler rod was the base metal I was going to be working with.

Working from the print, I had to make a 2" ID circle and leave enough for a 6" OAL with a small bend at the tip. I needed 18", or 1/2 of a rod, for each part. The first pics show the progression. I used a 1 5/8" tube to bend around as it was the right OD to provide the necessary springback to get the 2" ID. Then I clamped it to the table in position to be welded. The other two pics show both sides of the joint after welding. By pointing the tungsten at the cut end, it burned back ever so slightly to allow me to put a dab of .045" filler into the joint. A little blast of the pedal and it was a full pen joint, only having to heat one side.

More to come.
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Last edited by KB Fabrications; 12-10-2007 at 10:41 PM.
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  #2  
Old 10-18-2007, 01:59 PM
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Next comes the bending. I set up a small wire bending jig so that they all would end up the same length. At this point, the circles are welded/finished but the final length is not set. The first two pics show the bending progression. The next pic shows the part after bending and dressing the tip. For the tip length, I cut each one about 1/16" long and then ground to final length using a go, no go guage. The last pic shows all the little soldiers after passivating/cleaning.
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I've been crawling on my belly, clearing out what could've been. I've been wallowing in my own chaotic and insecure delusions. I wanna feel the change consume me, feel the outside turning in. I wanna feel the metamorphosis and cleansing I've endured within.
My shadow. Change is coming. Now is my time. Listen to my muscle memory. Contemplate what I've been clinging to.


Maynard James Keenan

Last edited by KB Fabrications; 12-10-2007 at 10:43 PM.
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Old 10-18-2007, 02:00 PM
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Nice weld was that piece work or hourly rate I used to do that with my stubs but not that pretty. nice job!
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Old 10-18-2007, 02:04 PM
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The first two pics are the before/after cleaning shots. I have a small shop made passivating unit I use to clean the weld burn off of all the stainless work I do. It is nothing but a box with a 110V to 12V transformer, a piece of copper tube crimped on both ends for a wand, and a cheap ground clamp. The only thing I don't have a pic of is the cloth that is wrapped around the business end of the wand. It needs to be soaked in an 85% phosphoric acid solution, from your local chemical supply. When you turn it on, you then connect the ground to what you are cleaning and use the PA soaked wand to rub over the affected area. Like magic, the weld burn will disappear leaving a beautiful shiny silver finish behind.

This is a rediculously simple thing to build. When you are using it, and it's working, all you notice is a small vibrating sensation while the cleaning is being done. The PA will dissipate rather quickly so you need to keep the wand/cloth loaded with it. You also don't want to touch any part of the bare copper wand to the part while it is grounded or you will get burn marks on the material you are trying to clean. I can't think of anything else but if you have specific questions, I will try to answer them.
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I've been crawling on my belly, clearing out what could've been. I've been wallowing in my own chaotic and insecure delusions. I wanna feel the change consume me, feel the outside turning in. I wanna feel the metamorphosis and cleansing I've endured within.
My shadow. Change is coming. Now is my time. Listen to my muscle memory. Contemplate what I've been clinging to.


Maynard James Keenan

Last edited by KB Fabrications; 12-10-2007 at 10:47 PM.
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Old 10-18-2007, 02:09 PM
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Quote:
Originally Posted by digr View Post
Nice weld was that piece work or hourly rate I used to do that with my stubs but not that pretty. nice job!
Hey thanks. This work was hourly rate.
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I've been crawling on my belly, clearing out what could've been. I've been wallowing in my own chaotic and insecure delusions. I wanna feel the change consume me, feel the outside turning in. I wanna feel the metamorphosis and cleansing I've endured within.
My shadow. Change is coming. Now is my time. Listen to my muscle memory. Contemplate what I've been clinging to.


Maynard James Keenan
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Old 10-18-2007, 02:11 PM
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That looks like something for the projects list. What is on the wand in the pic or did I miss something?
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  #7  
Old 10-18-2007, 02:15 PM
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Quote:
Originally Posted by digr View Post
That looks like something for the projects list. What is on the wand in the pic or did I miss something?
I think it was in the post but it is just a piece of copper tubing crimped at both ends. It has a hole drilled in each end for the connections and a piece of garden hose for a cover. I didn't get a pic of the wand loaded with cloth so all you see is the bare end.

EDIT: I'm about to make another one of these so if you guys are interested, I could do a thread on it.
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I've been crawling on my belly, clearing out what could've been. I've been wallowing in my own chaotic and insecure delusions. I wanna feel the change consume me, feel the outside turning in. I wanna feel the metamorphosis and cleansing I've endured within.
My shadow. Change is coming. Now is my time. Listen to my muscle memory. Contemplate what I've been clinging to.


Maynard James Keenan
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Old 10-18-2007, 03:22 PM
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Please do and explain the term passivate as it applies.
The dictionary definition doesn't really do it justice, imo. For instance:
Quote:
To treat or coat (a metal) in order to reduce the chemical reactivity of its surface.
To coat (a semiconductor, for example) with an oxide layer to protect against contamination and increase electrical stability.
Fine, but why phosphoric, etc.?
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Old 10-18-2007, 04:17 PM
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Quote:
Originally Posted by cutter View Post
Please do and explain the term passivate as it applies.
The dictionary definition doesn't really do it justice, imo. For instance:


Fine, but why phosphoric, etc.?
EDIT: So a quick google search turned up a good explanation of "passivation" of stainless steels. I suspect my reference to passivation comes from us lay types in the industry latching onto a term but not really understanding what it means.

What It Is and How It Works!

Passivation

There is some dispute over whether the corrosion resistance of stainless steel can be enhanced by the process of passivation. Essentially, passivation is the removal of free iron from the surface of the steel. This is performed by immersing the steel in an oxidant, such as nitric acid or citric acid solution. Since the top layer of iron is removed, passivation diminishes surface discoloration. While passivation does not affect the thickness or effectiveness of the passive layer, it is useful in producing a clean surface for a further treatment, such as plating or painting. On the other hand, if the oxidant is incompletely removed from the steel, as sometimes happens in pieces with tight joints or corners, then crevice corrosion may result. Most research indicates that diminishing surface particle corrosion does not reduce susceptibility to pitting corrosion.


This was taken from this website: http://chemistry.about.com/cs/metals...a071201a_2.htm

Here is the google search for passivate stainless steel: http://www.google.com/search?sourcei...tainless+steel

Looks like I will be doing some homework for this one.
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I've been crawling on my belly, clearing out what could've been. I've been wallowing in my own chaotic and insecure delusions. I wanna feel the change consume me, feel the outside turning in. I wanna feel the metamorphosis and cleansing I've endured within.
My shadow. Change is coming. Now is my time. Listen to my muscle memory. Contemplate what I've been clinging to.


Maynard James Keenan

Last edited by KB Fabrications; 10-18-2007 at 04:25 PM.
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Old 10-18-2007, 04:45 PM
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Pretty impressive, Kevin. And, as always, Nice welds.
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