Spray arc 2

[Rocky D]

The project started out like this...5 1/2" hot rolled steel plate.

[Rocky D]

Then this piece had to be built to go on top. My underpowered M-25 torch is laying beside it. It got cherry red after a pass. The machine I used is a CP300 Miller. (of course)

[Rocky D]

The chamfer I did using a Victor machine cutter, you will see later when I hitched my MIG torch to it. The inset piece is 4" thick the rest is 2"

[Rocky D]

Here it is in place ready to weld. The parts had heave mill scale on them, so I used a air needle scaler to break up the scale, and di a lot of grinding to get the weld areas to base metal.
The pesi can is to show relative size

[Rocky D]

To weld it, I had to build this frame to hold it in a 45 degree position. This helps to pour the weld metal in.

[Rocky D]

Two passes

[Rocky D]

Third pass...done by hand...closer view

[Rocky D]

Now I get innovative...I did the whole joint with this. At one point, my glove and sleeve parted, and I got a radiation burn that took two weeks to heal. It just goes to show just because you have experience doesn't mean you can't make mistakes...BE SAFE OUT THERE!

[Rocky D]

A closer look at the results...always in welding, the results governs the procedure

[GWOL]

Cool Rocky! I only have one question do you think I would be albe to do something like that with my hh135? :)

[Rocky D]

Here it is after stress relieve and Blanchard grinding before machining. The two 4" square columns were removed after machining.

[Rocky D]

The hydraulic manifold, all GTAW

[Rocky D]

A closer look of the manifold

[Rocky D]

After machining

[Bob]

A foot for an Imperial Walker (Starwars).
A wheel chock for an air craft carrier.
A fixture to weld something even bigger.

Don't tell us right off, maybe some other readers have some interesting ideas.

Bob

[Rocky D]

Ready to install with manifold mounted

[Rocky D]

The finished product...200 ton Sheridan Stretch Bend Forming machine. Saved the company 1.5 million by welding these up in house.

[Rocky D]

By now you're sick of looking at all of this, I apologise, but here's a closer look at the jaw plate installed

[GWOL]

Rocky,

dont apologise, it is amazing to see that kind of work. Still not sure what it is, but still neat to see the process you went through. I thought this forum was great before, but now with the images to see some of this great work, and the projects people have done, its just that much better.

Keep up the great work! :)

[Rocky D]

Thanks for the kind words, Gary. About half of the folks who come here are fairly new to welding, and some are contemplating welding as a career. These projects I have done are only what one man can do with this trade. If I can do it, anyone with a little practice can do it, too. We as weldors are only limited by our imagination. For me, it is still fun!

[Brent]

Rocky, I too agree with GWOL. I find the posts with pictures very fascinating. I reviewed each one and really appreciate the skill and talent that you clearly have. Sure hope saving the company $1.5 million was well rewarded.

Brent

[Rocky D]

Originally posted by Brent
Rocky, Sure hope saving the company $1.5 million was well rewarded.

Brent

The overtime was worth it, and they took my picture.

:rolleyes:

[Bobby]

Holy smokes. that's a lot of metal. each picture got more and more intriguing until you finally get to see where that huge hunk of steel goes.

Looks like a mighty fine job.

[morpheus]

wow ... thanks for sharing the work and pics Rocky. got any pics of the device in action ?

that's very nice work. How long have you been a weldor ?

- jack

[Rocky D]

Originally posted by morpheus
wow ... thanks for sharing the work and pics Rocky. got any pics of the device in action ?

that's very nice work. How long have you been a weldor ?

- jack

I'll try to post a picture of the machine pulling a part. I don't have one yet, tho.

I've been welding about 45 years, and I think I just might make it a career...it's still fun!

[morpheus]

45 yrs ... that's quite a career at it Rocky ! you are definitely
a professional.

I'd really be interest in seeing that machine make a part, I can't
even envsion how the thing works.

Question: in one of the pics you posted you showed using a track
torch with the mig gun attached to make a pass. I could see how this would work but since the track torch just runs straight it wouldn't "weave" any. Is that not a concern or is that such big wire that it doesn't matter. perhaps this is a dumb question. i'm definitely a welding amateur even though I've been trying at home for going on 6 yrs :o

- jack

[Rocky D]

Originally posted by morpheus

Question: in one of the pics you posted you showed using a track
torch with the mig gun attached to make a pass. I could see how this would work but since the track torch just runs straight it wouldn't "weave" any. Is that not a concern or is that such big wire that it doesn't matter. perhaps this is a dumb question. i'm definitely a welding amateur even though I've been trying at home for going on 6 yrs :o

- jack

No question is dumb, Jack. In spray transfer mode, there's no need to weave. A straight pass is 3/4" wide, and I could weave a 1 1/2" pass by hand. I do it to lay down more metal in one pass, and the weldment was so big, I could experiment, and not have to worry about warping. I had a + or - .500" tolerance. A good deal of production welding is robotic spray transfer, in the industry today, so I thought it would be cool to try it. At one point, I fried my wrist, when the glove and sleeve parted. That stuff is hot!!

[morpheus]

ahhh ... that clears it up for me Rocky. Thanks ;)

Another question I have is when I have tried to spray arc myself instead of just short circuit welding I almost always end up with little "stovepipe" looking holes coming up in the weld bead. Is this because my surfaces are not clean enough or my technique is wrong or ???

- jack

[Rocky D]

Originally posted by morpheus
ahhh ... that clears it up for me Rocky. Thanks ;)

Another question I have is when I have tried to spray arc myself instead of just short circuit welding I almost always end up with little "stovepipe" looking holes coming up in the weld bead. Is this because my surfaces are not clean enough or my technique is wrong or ???

- jack

It sounds like a gas problem, Jack. Not getting good coverage, could be not enough pressure, a leak in the line somewhere, wind blowing gas away, too much stick out. Presence of oil and other dirt could do it, too. In the big job I did, I would occasionally get holes, like swiss cheese, too. You just have to carbon arc them out and go over it. And sometimes there's just no rhyme or reason for it. This is 1 1/4" wide, done by hand. 1/16" E70S-6 98-2 CO2

[morpheus]

I think my problems with spray arcing are likely wind blowing the gas away. Now that you mention that I believe every time I've had the holes occur i've had my shop fan pointed at where I was working when normally I'd shut it off or point it the other direction before I'd start welding. Thanks for the tip Rocky !

- jack

[Rocky D]

Here is a picture of the monster machine in working mode. All the clamps are in place. the die on the middle is what the metal gets streched over. The part o the right is perforated aluminum

[Rocky D]

another shot of it ready to go to work