|
dv6speed posted:How in the world do you even position the 2 pieces for welding... cranes? What was that you were welding btw? A chemical reactor. 21' Diameter vessel with 7" wall thickness. I forget what type it was but it was a stainless steel. You position them with cranes, and rollers. You put one piece onto rollers, then bring the next piece up to it with a crane. Now with such pieces being so big and awkward to work with, you have to have your rigging set up just so to make sure everything lines up. Then you put BIG rear end tacks all over it. 1 1/2" Fillet welds on 8 gussets straddling the joint. After that you sub arc it for 56 hours nonstop and presto! One joint complete. Edit: The vessel shells were made by Japan Steel Works, they forge a big huge cylinder of the material you want, then they jam a shaft through the centre to form the shape of the vessel walls. Check the pic of the forging and remember that thing is probably 20' diameter or bigger. http://www.jsw.co.jp/en/product/material/vessel/fabsequence.html SmokeyXIII fucked around with this message at 04:19 on Aug 22, 2008 |
# ? Aug 22, 2008 04:11 |
|
|
# ? Mar 29, 2024 08:19 |
|
SmokeyXIII posted:A chemical reactor. 21' Diameter vessel with 7" wall thickness. I forget what type it was but it was a stainless steel. You position them with cranes, and rollers. You put one piece onto rollers, then bring the next piece up to it with a crane. Now with such pieces being so big and awkward to work with, you have to have your rigging set up just so to make sure everything lines up. Then you put BIG rear end tacks all over it. 1 1/2" Fillet welds on 8 gussets straddling the joint. After that you sub arc it for 56 hours nonstop and presto! One joint complete.
|
# ? Aug 22, 2008 04:29 |
|
SmokeyXIII posted:
Well, I have a huge boner. Anyone else? Slung Blade fucked around with this message at 04:35 on Aug 22, 2008 |
# ? Aug 22, 2008 04:30 |
|
Dongsmith posted:this is crazy. sub-arc meaning submerged arc welding? Yep. It's about the most boring thing ever, which leads to not paying attention, which leads to HUGE mistakes due to the high heat input and deposition rates. So no one really wants to do the job. Also you're sitting on a piece thats heated up to 350 or more degrees.. Basically it leaves footprints when you walk on top of it because it melts your boots.
|
# ? Aug 22, 2008 04:33 |
|
Slung Blade posted:Well, I have a huge boner. Anyone else? Look at the hand rail for scale.
|
# ? Aug 22, 2008 04:34 |
|
I would love to have a power hammer, maybe not quite that big, but I'm sure I could use it...
|
# ? Aug 22, 2008 04:41 |
|
SmokeyXIII posted:Yep. It's about the most boring thing ever, which leads to not paying attention, which leads to HUGE mistakes due to the high heat input and deposition rates. So no one really wants to do the job. 100lb/hr is pretty nuts. Was that a continuous weld? edit: yes it was
|
# ? Aug 22, 2008 04:42 |
|
Slung Blade posted:I would love to have a power hammer, maybe not quite that big, but I'm sure I could use it...
|
# ? Aug 22, 2008 04:46 |
|
Dongsmith posted:man, you can churn poo poo out with a little giant and a propane forge. I've never tried, but I am pretty sure it would be ridiculously easy (which is why people should start with hand hammers and coal) I used a gigantic air hammer made, poo poo, probably 80 years ago, when I did my course at a local pro's place. It was awesome, pure awesome. But I know what you mean, good to learn control and build the strength you need.
|
# ? Aug 22, 2008 04:51 |
|
Slung Blade posted:I used a gigantic air hammer made, poo poo, probably 80 years ago, when I did my course at a local pro's place. It was awesome, pure awesome.
|
# ? Aug 22, 2008 05:03 |
|
Yeah I'll be building one as soon as I get a shop built. Or buy one, if I can find a decent one that I can repair in fairly close proximity.
|
# ? Aug 22, 2008 06:49 |
|
Just did a casting with the new pattern. I used baby powder this time as parting compound which worked MUCH better. I also remembered to vent the mold this time. The sand had just a tad too much water in it, so there is a very minor steam defect on the casting that no amount of venting would have fixed. Overall I'm pleased. Time to go re-mull the sand and try again! I'm saving the defective castings until I have a chance to take a picture of them.
|
# ? Aug 22, 2008 17:28 |
|
Well did the 3rd casting. It came out PERFECT... except for yet another steam defect. I vented both the cope and drag in this casting and the last one. I think my sand may just have a little too much moisture. I'm considering the idea of making another mold today and letting it sit out for a day or 2. (Note you shouldn't HAVE to let your mold sit out to dry.)
|
# ? Aug 22, 2008 20:42 |
|
Would it help if you used a hair dryer for a few minutes before pouring? I was out pounding for a bit tonight, got done my other half of the pair of tongs I've been procrastinating over. I'll bend them tomorrow, prep the jaws, and rivet them together.
|
# ? Aug 23, 2008 04:49 |
|
dv6speed posted:Well did the 3rd casting. It came out PERFECT... except for yet another steam defect. How much steam are you seeing rising from the sand? Are your gates and risers big enough?
|
# ? Aug 23, 2008 05:08 |
|
I did a 3rd casting tonight (4th casting total.) It came out great, best yet, but it has a tiny steam defect that prevents it from being usable. We are talking a very small defect. We'll try again tomorrow.Punzilupo posted:Are you sure it's not shrinkage? I'm positive it's not shrinkage... If I had pictures you'd see what I mean. The sand just has a tad too much water. Each successive casting today came out better and better from the sand drying out and being re-mulled. Greensand is very very picky about it's moisture content. It is supposed to have enough moisture to hold together, but dry enough that metal can be poured into it right away. Slung Blade posted:Would it help if you used a hair dryer for a few minutes before pouring? I currently have a good portion of sand drying out on a tarp in my garage, so I can re-mull it to the correct moisture content tomorrow morning. Edit: All this mulling reminds me... I need to build a motorized sand muller! I need one anyway if I want to use petrobond. Petrobond sand MUST be mulled my machine. AbsentMindedWelder fucked around with this message at 05:32 on Aug 23, 2008 |
# ? Aug 23, 2008 05:29 |
|
dv6speed posted:Greensand is very very picky about it's moisture content. It is supposed to have enough moisture to hold together, but dry enough that metal can be poured into it right away. Also if you aren't making allowances for small surface defects you should re-consider your pattern, and be willing to spend time filing (or cutting or machining) away the excess.
|
# ? Aug 23, 2008 06:16 |
|
I've been hunting around on craigslist for an anvil, since I'm interested in doing some more hammer work, but I've been balking at the $150 to $400 price tag I've seen on them. However, I happened to swing by a garage sale today, and the guy was selling his late father-in-law's old metal working tools. And I found this: It's not a big anvil (just 25lbs and 19" long, made from a railroad tie), but as I'm only really working with automotive-sized sheet metal, nails and coat-hangers, this thing is perfect. Total price: $6. And that included the hammer. Woo hoo.
|
# ? Aug 23, 2008 23:09 |
|
jovial_cynic posted:I've been hunting around on craigslist for an anvil, since I'm interested in doing some more hammer work, but I've been balking at the $150 to $400 price tag I've seen on them. However, I happened to swing by a garage sale today, and the guy was selling his late father-in-law's old metal working tools. And I found this: Railroad anvils are a great start. Hooks and Nails are good tapering practice, and they're just about the right size stock for that much anvil mass.
|
# ? Aug 24, 2008 02:04 |
|
Nice find with that railroad track anvil! Good luck smithin'! Today was a good foundry day. I've finally been able to mull good sand! Between good sand and good venting, the steam defect issue is solved. Now that I have the steam issue solved, I now can finally see real signs of shrinkage. I will make bigger sprues, risers, and gates tomorrow. Everything is finally falling in place now. I think I should have some really nice castings tomorrow. The goal right now is to produce a metal casting that can be cleaned up and used as a pattern itself.
|
# ? Aug 24, 2008 04:21 |
|
Great news! I have a perfect casting! I'll have some pictures soon. In other good news, I start welding school tomorrow morning!
|
# ? Aug 25, 2008 03:04 |
|
dv6speed posted:Great news! Tell us all about it!!
|
# ? Aug 25, 2008 23:36 |
|
This is a true story: I'm going to build a forge this winter. Half to add to my metal-working inventory, and half to keep warm while staying outside, because outside is more fun than inside.
|
# ? Aug 25, 2008 23:43 |
|
SmokeyXIII posted:Tell us all about it!! Well, I will now disclose that the casting is a grenade shaped paperweight. I'll have pictures of it soon. It may eventually be for sale on SA mart, but I would have to improve/perfect/speed up the casting and finishing process, and then sit down and figure out what my time and materials are worth. It looked as tho it'd be a simple casting project... well it's not. The sand space between the body and handle is a challenge to keep together, but possible. Using the proper moisture content in the sand fixed the steam defect issue. There was also a shrinkage issue, but wasn't evident until the steam problem was resolved. That was fixed with larger a sprue, riser, and gates. Welding school went well today. The instructors are nice and knowledgeable gentlemen. This welding program (among other various trades) is provided to me free of charge, and is paid for by my state's department of labor. This costs them about $5k a head. The school and instructors help the students who complete the course secure good jobs. One interesting fact is that if I don't get a welding job within 90 days of completion, the school does NOT get paid! In any event, most of today was dealing with bureaucracy, paperwork, and other formalities. We started to touch on safety. The first 1.5 weeks or so is spent in the classroom dealing with safety and theory. In other news, UPS showed up at my door right on time with my new clay-graphite crucible. It looks pretty good, the outside measurements are 5"x7.5". So I'm thinking about a 9"x12" ID furnace. Considering my refractory will be 2.5" thick, I need a shell of 14"x14.5" ID. Edit: Furnaces for oil burners should have more air space between the wall and crucible then with propane furnaces. AbsentMindedWelder fucked around with this message at 00:30 on Aug 26, 2008 |
# ? Aug 26, 2008 00:23 |
|
dv6speed posted:I was too tired last night to tell you about it, but I'm not now... You know that pretty much every army navy store sells actual grenade paperweights right?
|
# ? Aug 26, 2008 02:30 |
|
Here is what the completed casting looks like out of the sand, with the sprue and riser cut off. I've done some hacksawing and filing, but haven't finished it yet. It's about 3/4" thick, and weighs just over 13 oz.RealKyleH posted:You know that pretty much every army navy store sells actual grenade paperweights right?
|
# ? Aug 26, 2008 03:19 |
|
That looks like a pretty cool casting there Dv6, way to go man
|
# ? Aug 26, 2008 03:38 |
|
I just finished a five-day class on Japanese-style temperlines - taught by Don Fogg. So here is my second knife blade ever:
|
# ? Aug 27, 2008 00:29 |
|
Third Murderer posted:I just finished a five-day class on Japanese-style temperlines - taught by Don Fogg. I hear Don Fogg is the man.
|
# ? Aug 27, 2008 01:05 |
|
dv6speed posted:Nice! Anything good you've ever heard about him is most likely true. He's incredibly knowledgeable, very friendly and approachable, and a great teacher to boot. Anyone who's into bladesmithing and has the chance to take a class with him should do it.
|
# ? Aug 27, 2008 02:03 |
|
Third Murderer posted:I just finished a five-day class on Japanese-style temperlines - taught by Don Fogg. You son of a bitch GIVE ME YOUR SECRETS! But seriously, that's awesome man, it looks absolutely beautiful. Was it a clay temper?
|
# ? Aug 27, 2008 03:59 |
|
Well yesterday I did the single best weld of my entire life. I couldn't get my iPhone working last night but it worked tonight so maybe ill share the pictures! To be quite honest the pictures don't do it justice. My QC foreman came up to the weld and from 5 feet away he says "WHOA! that's a nice weld" Supposedly no one has ever heard him say that before. It was even in a pretty awkward position too, notice how close the scaffold was to the joint, it left for very little room to move, and even worse because there was a horizontal elbow which left even less room on the one side. I'm sorry if they look the same as the last picture but gosh I am sure proud of these ones.
|
# ? Aug 27, 2008 04:32 |
|
SmokeyXIII posted:I'm sorry if they look the same as the last picture but gosh I am sure proud of these ones.
|
# ? Aug 27, 2008 11:16 |
|
dv6speed posted:Holy cow! That is one hell of a nice pipe weld man, you should be proud. What sized pipe and what type electrodes is that? 10" Sch 40. About 1/2" thick? It's not too big. I used mostly 3/32 7018, only a little bit of 1/8 on the fill but I decided that was looking stupid so I went back to 3/32. Also I use 1/8 6010 for the root pass.
|
# ? Aug 27, 2008 12:59 |
|
Now that I've got a little anvil, I'm thinking about building a forge. I have an old oversized woodstove that I picked up for free that included woodstove firebricks. Any words of advice or caution regarding converting it into a forge? Also, does anybody know what it typically costs to have a machine shop mill down the surface of a 19-inch section of railroad track? I'd like the surface to be smooth, but if it's going to cost me $100 to do it, I'd just as soon save up and buy a proper anvil.
|
# ? Aug 27, 2008 22:19 |
|
quote:Also, does anybody know what it typically costs to have a machine shop mill down the surface of a 19-inch section of railroad track? I'd like the surface to be smooth, but if it's going to cost me $100 to do it, I'd just as soon save up and buy a proper anvil.
|
# ? Aug 28, 2008 00:20 |
|
I don't know if we care about this in this thread but today I went to Syncrude, which is a different plant than the one I work at, and we checked out all the old mining equipment. I stood in the shovel. It's huge but compared to the new ones its so tiny. They've got all kinds of huge equipment up there, it was just so amazing to see the gigantic metal monsters up so close. Pretty neato! http://i486.photobucket.com/albums/rr224/SmokeyXIIII/IMG_0033.jpg
|
# ? Aug 28, 2008 03:24 |
|
SmokeyXIII posted:I don't know if we care about this in this thread but today I went to Syncrude, which is a different plant than the one I work at, and we checked out all the old mining equipment. I stood in the shovel. It's huge but compared to the new ones its so tiny. They've got all kinds of huge equipment up there, it was just so amazing to see the gigantic metal monsters up so close. Pretty neato! Did you see any ravens big enough to carry off a small child? Nice picture, I'd like to visit Ft Mac someday, it's not that far. jovial_cynic posted:Now that I've got a little anvil, I'm thinking about building a forge. I have an old oversized woodstove that I picked up for free that included woodstove firebricks. Any words of advice or caution regarding converting it into a forge? The bricks should be fine. Are you going to use any kind of mortar to join them together or just dry fit them? If you use mortar, make sure it's fire-rated. Can you post a picture of it? I can't say what kind of a forge it would make without seeing it first. Slung Blade fucked around with this message at 04:42 on Aug 28, 2008 |
# ? Aug 28, 2008 04:39 |
|
SmokeyXIII posted:I don't know if we care about this in this thread but today I went to Syncrude, which is a different plant than the one I work at, and we checked out all the old mining equipment. I stood in the shovel. It's huge but compared to the new ones its so tiny. They've got all kinds of huge equipment up there, it was just so amazing to see the gigantic metal monsters up so close. Pretty neato! where are you working at? that looks eerily familiar to some steam piping we're having welded up here at the brewery
|
# ? Aug 28, 2008 04:53 |
|
|
# ? Mar 29, 2024 08:19 |
|
Slung Blade posted:You son of a bitch GIVE ME YOUR SECRETS! Okay! I'll type up my notes when I have the time, hopefully tonight. Slung Blade also posted:But seriously, that's awesome man, it looks absolutely beautiful. Was it a clay temper? Yes, we thinly coated the blade with clay to help prevent scale, then painted on ashi lines and a thicker coating along the back.
|
# ? Aug 28, 2008 17:25 |