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Metalworking (rec.crafts.metalworking) Discuss various aspects of working with metal, such as machining, welding, metal joining, screwing, casting, hardening/tempering, blacksmithing/forging, spinning and hammer work, sheet metal work. |
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#1
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need welding tricks.... keeping things cool
I have a BUNCH of shafts that need to be welded (using tig) on the end
to secure an arm that is swaged onto the shaft. The weld will be about .375 long, bonding the arm to the shaft. Directly behind the arm, with about .250 clearance is a nylon bushing.... I don't want to melt the bushing when welding. I have to weld a bunch of these... in the hundreds. MIG welding puts too much of a bubble there, and the tig looks OH soooo much nicer. I need an easy setup to weld this without putting heat into the nylon bushing. I rigged up a small air nozzle to blow on the backside of the arm to keep things cool.... I cannot seal the airflow from getting around to the front because the design of the arm has a few screw holes in it, I think the air flow from the nozzle is disrupting my welding gas. So I was thinking about how I could eliminate the air flow, and I had an idea this morning about submerging the shaft in water, with the weld area above the water line. Now I would not be attempting this without asking the group here about the impending dangers.... foremost on my mind would be electric shock.... so please, if you have positive and helpful remarks / suggestions I am all ears. |
#2
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need welding tricks.... keeping things cool
wrote: (clip) impending dangers.... foremost on my mind would be electric shock....(clip) ^^^^^^^^^^^^^^^^^^ The water, the workpiece , your bench and the ground cable will all be at the same potential. Go for it--the water will certainly keep things cool. If you do a lot of these in quick succession, the water may start to get hot. I'm sure you can deal with that. Ice cubes? ;-) |
#3
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need welding tricks.... keeping things cool
an idea this morning about submerging the shaft in water, with the
weld area above the water line. Now I would not be attempting this without asking the group here about the impending dangers.... foremost on my mind would be electric shock.... so please, if you have positive and helpful remarks / suggestions I am all ears. I've done this often with great success. Karl |
#4
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need welding tricks.... keeping things cool
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#5
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need welding tricks.... keeping things cool
wrote in message I have a BUNCH of shafts that need to be welded (using tig) on the end to secure an arm that is swaged onto the shaft. The weld will be about .375 long, bonding the arm to the shaft. Directly behind the arm, with about .250 clearance is a nylon bushing.... I don't want to melt the bushing when welding. I have to weld a bunch of these... in the hundreds. MIG welding puts too much of a bubble there, and the tig looks OH soooo much nicer. I need an easy setup to weld this without putting heat into the nylon bushing. Another thought. Set up vise grip pliers with copper jaws to act as a heat sink. The jaws could even be water cooled since you have 100's to do. The copper should be a close fit, perhaps even use silicone heat sink compound to help conduction. Phil -- Posted via a free Usenet account from http://www.teranews.com |
#6
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need welding tricks.... keeping things cool
"Phil Kangas" wrote: (clip) Set up vise grip pliers (clip) ^^^^^^^^^^^^^^^^^^ Try to find a pair of Ice-grips. Meant as a joke, but actually, that might work. Pre-cast properly shaped blocks of ice that could be held between the weld and the nylon with a rubber band. |
#7
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need welding tricks.... keeping things cool
Get some air-conditioning, copper, capillary tubing and circulate water
through it after wrapping the Nylon bushing and shaft with it. wrote in message oups.com... I have a BUNCH of shafts that need to be welded (using tig) on the end to secure an arm that is swaged onto the shaft. The weld will be about .375 long, bonding the arm to the shaft. Directly behind the arm, with about .250 clearance is a nylon bushing.... I don't want to melt the bushing when welding. I have to weld a bunch of these... in the hundreds. MIG welding puts too much of a bubble there, and the tig looks OH soooo much nicer. I need an easy setup to weld this without putting heat into the nylon bushing. I rigged up a small air nozzle to blow on the backside of the arm to keep things cool.... I cannot seal the airflow from getting around to the front because the design of the arm has a few screw holes in it, I think the air flow from the nozzle is disrupting my welding gas. So I was thinking about how I could eliminate the air flow, and I had an idea this morning about submerging the shaft in water, with the weld area above the water line. Now I would not be attempting this without asking the group here about the impending dangers.... foremost on my mind would be electric shock.... so please, if you have positive and helpful remarks / suggestions I am all ears. |
#8
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need welding tricks.... keeping things cool
wrote in message oups.com... So I was thinking about how I could eliminate the air flow, and I had an idea this morning about submerging the shaft in water, with the weld area above the water line. Now I would not be attempting this without asking the group here about the impending dangers.... foremost on my mind would be electric shock.... so please, if you have positive and helpful remarks / suggestions I am all ears. Hundreds of them? Dunk them. The only other solution I can think of would be to use a pressurized water mist, but that's probably messier than a dunk tank and might not pull the heat away fast enough. Possibly some type of wetting agent and/or a circulating pump may be necessary. I'm assuming that both pieces to be welded are a mild steel? |
#10
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need welding tricks.... keeping things cool
On Tue, 11 Sep 2007 08:58:24 -0700, wrote:
I have a BUNCH of shafts that need to be welded (using tig) on the end to secure an arm that is swaged onto the shaft. The weld will be about .375 long, bonding the arm to the shaft. Directly behind the arm, with about .250 clearance is a nylon bushing.... I don't want to melt the bushing when welding. I have to weld a bunch of these... in the hundreds. MIG welding puts too much of a bubble there, and the tig looks OH soooo much nicer. I need an easy setup to weld this without putting heat into the nylon bushing. Nu-Calgon Thermo-Trap heat sink paste - available at welding and refrigeration supply houses. Goes on like toothpaste, and sticks and cools the item it's coating (like a refrigeration ball valve or reversing valve) while you braze the valve in a half inch away. http://ftp.nucalgon.com/ftp/prodlit/3-61.pdf (800K) For a production line situation like this, couldn't you install the nylon bushings AFTER the welding process? And if they come installed in the part pull them out, do the work, then press them back in. A bit more work to R&R but no material costs for the heat sink paste compound (or whatever method you settle on), and zero chance of melting the nylon because it's 5 feet away... -- Bruce -- |
#11
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need welding tricks.... keeping things cool
UPDATE on this... I welded up a water tight pipe to hold the shaft
that I have to weld on in place, and filled up the pipe with water right to the brim and welded 10 of these shafts, and the water kept the bushing from melting. I had to switch the water out after 4 shafts, as it was pretty hot. This is EXACTLY what I needed to help me out. THANKS! |
#12
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need welding tricks.... keeping things cool
On Sep 11, 5:52 pm, Ignoramus26973
Directly behind the arm, with about .250 clearance is a nylon bushing.... I I do not think that there is any way to avoid damaging the bushing that is .250 away from the weld. i I think he means the weld is on the other side of the arm plus another 1/4 inch to the bushing. Dan I rigged up a small air nozzle to blow on the backside of the arm to keep things cool.... I cannot seal the airflow from getting around to the front because the design of the arm has a few screw holes in it, I think the air flow from the nozzle is disrupting my welding gas. |
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