Welding Tips and Tricks

Otto Nobedder wrote:I make less than him, too!

I've made far more, and hated my job.

There's some wisdom the 18yo's can try to absorb.

I love what I do, and enjoy going to work every morning.

Steve S

That's crazy to me that I make more than both of y'all. Kinda makes me mad a bit, cause I guarantee you're both a thousand times better and smarter than me.

What codes did y'all qualify to (if any), that way I can start expanding my library, and anyone else that is so inclined can know.

Welding is my dream work. I like where I am, but it is starting to get boring welding the same shit every single day. They have amazing benefits here, good, scheduled pay raises, I could retire at 55 with over a million in my 401k, not to mention pension. It takes good care of my family.

I have a couple welders in the garage at home, and I'm trying to get more/better equipment. Any way I could do aerospace as a side job? Lol

What I don't like is the emphasis on speed, sometimes at the sacrifice of quality. I bet you two can do one thing all day and make it 100% perfect. Maybe I oughtta make me a spaceship at home... Lol

RocketSurgeon, did you ever think of working for spacex? I bet they pay pretty good.

Otto Nobedder wrote:I make less than him, too!

I've made far more, and hated my job.

There's some wisdom the 18yo's can try to absorb.

I love what I do, and enjoy going to work every morning.

Steve S

Steve,
I'm no expert at what your job entails, but I know what you do. I've seen your posts and pics of your "daily grind". I have nothing less than total respect for your dedication and admire your earned skill (is your head swollen, yet ).

My goal, after passing all my weld tests in the upcoming class, is to have the confidence that I can add your skill to my dedication in aerospace. Everyday that goes by here at Michoud adds to my experience, but we all know it means squat without the understanding, knowledge and skill of metalwork.

nathan wrote:
That's crazy to me that I make more than both of y'all. Kinda makes me mad a bit, cause I guarantee you're both a thousand times better and smarter than me.

What codes did y'all qualify to (if any), that way I can start expanding my library, and anyone else that is so inclined can know.

Welding is my dream work. I like where I am, but it is starting to get boring welding the same shit every single day. They have amazing benefits here, good, scheduled pay raises, I could retire at 55 with over a million in my 401k, not to mention pension. It takes good care of my family.

I have a couple welders in the garage at home, and I'm trying to get more/better equipment. Any way I could do aerospace as a side job? Lol

What I don't like is the emphasis on speed, sometimes at the sacrifice of quality. I bet you two can do one thing all day and make it 100% perfect. Maybe I oughtta make me a spaceship at home... Lol

RocketSurgeon, did you ever think of working for spacex? I bet they pay pretty good.

Nathan,
We don't use national code. Everything is either MILSPEC or NASASPEC. Very specific and extreme tolerance (sometimes .0001"). Most of the time we only get one chance at the work in front of us. It has to be perfect the first time, every time. Astronaut lives are depending on us (my whole aerospace career has been in Man-rated vehicles).

I think about McGregor, TX. (SpaceX R&D facility) every time I see my paycheck. But, I just can't talk myself into leaving NASA for a another corporation.

If your REALLY want in on aerospace welding, TIG. TIG Al. TIG Al till you are sick of it. Then TIG some more. We use a specific technique to maintain weld purity inside the bead. DC reverse with pure, dry He. This is not a place where speed pays. Only dedication, honesty and confidence in your work will get your acknowledged. (It also helps that it is inside, "OCD" clean, all tools and machines are provided, climate controlled and we have a cafeteria. )

Nathan,

The only code I'm held to is ASME boiler code, to sections B31.3 and B31.9 (which apply to only a small fraction of my work). Amazingly, I'm not required to even qualify to AWS D1.1 to weld sub-frames and other structure on these tankers that weigh 23+ tons empty.

I have qualified to D1.1 several times in the past, so I'm confident, but we rely primarily on the client's over-engineering to ensure a zero failure rate on the structural stuff. It works. In 60 years or so, they've not had a major disaster, and have not had a major incident that was caused by a weld failure in the structure.

Steve S

Wow, thanks an awesome success rate! Feel any pressure when you work to not be "the guy" that had the bad tank? Lol

RocketSurgeon, I understand that DC Al needs to be ridiculously clean. What is your cleaning regimen?

nathan wrote:RocketSurgeon, I understand that DC Al needs to be ridiculously clean. What is your cleaning regimen?

If you are asking about pre-weld prep (for Friction Stir or TIG), we scotchbrite (120 grit blue pads) to new metal and then wipe down with acetone and then Isopropyl Alcohol with lint free cloth. We have to begin welding within 48hrs. or we end up violating our clean time and have to start all over.
If you are asking about the TIG weld itself, DC- at 115-135A (depending on thickness) with 20cfm dry, pure He shield gas with a 2% Thoriated Tungsten.

What kind of issues can you encounter with friction stir? I.E. inclusions, porosity, etc.

nathan wrote:What kind of issues can you encounter with friction stir? I.E. inclusions, porosity, etc.

Porosity is our biggest issue. Luckily, it's all robotic. CNC controlled. Highly repeatable.
As far as inclusions, as long as the prep is right, the parent material is pure/clear and we don't have a bug land in the weld lan (TamJeff ).

RocketSurgeon wrote:

nathan wrote:RocketSurgeon, I understand that DC Al needs to be ridiculously clean. What is your cleaning regimen?

If you are asking about pre-weld prep (for Friction Stir or TIG), we scotchbrite (120 grit blue pads) to new metal and then wipe down with acetone and then Isopropyl Alcohol with lint free cloth. We have to begin welding within 48hrs. or we end up violating our clean time and have to start all over.
If you are asking about the TIG weld itself, DC- at 115-135A (depending on thickness) with 20cfm dry, pure He shield gas with a 2% Thoriated Tungsten.

Really! I've always been told never to clean AL with scotchbrite as it will leave micro particles embedded and cause contamination. Can you provide a link to show what you use?

Thanks

I think this comes from using Scotchbrite on old metal. If there's any texture to the metal surface, you can trap particles.

On new clean metal this is unlikely, and the acetone and IPA washes should remove any minor residue.

Steve S

Otto Nobedder wrote:I think this comes from using Scotchbrite on old metal. If there's any texture to the metal surface, you can trap particles.

On new clean metal this is unlikely, and the acetone and IPA washes should remove any minor residue.

Steve S

Still if the owner caught me doing this then I'd get an earful

If NASA specs it for "Man-Rated" vehicles, your dickhead boss has little argument against it.

Otto Nobedder wrote:If NASA specs it for "Man-Rated" vehicles, your dickhead boss has little argument against it.

Boom.
Did you hear that?
That was a truth bomb.

Otto Nobedder wrote:If NASA specs it for "Man-Rated" vehicles, your dickhead boss has little argument against it.

Bet you can guess I'd like to show him that spec.

Otto Nobedder wrote:I think this comes from using Scotchbrite on old metal. If there's any texture to the metal surface, you can trap particles.

On new clean metal this is unlikely, and the acetone and IPA washes should remove any minor residue.

Steve S

Once again, you are correct , sir.

The washes are to remove dust left over from the Scotchbrite and oxidized Al. We do allow a few minutes time for both washes to evaporate completely and we are required (with good reason) to handle all cleaned parts with nitrile or cotton gloves.

Umm,

https://www.amazon.com/Audel-Welding-Po ... +Reference

What do you think about this book?

cherwolf wrote:Umm,

What do you think about this book?

Looks pretty good to me! Get it and report back how you like it.

cherwolf wrote:Umm,

https://www.amazon.com/Audel-Welding-Po ... +Reference

What do you think about this book?

It's definitely a worthwhile purchase. I bought one when Jody recommended it in a video. Lots of good info in it.

Metals and how to weld them is ordered. It costs $12.50 + $3.61 shipping. From lincoln foundation. Some guys at Amazon are selling them for $33...

The PDF's and charts posted on Miller's site
https://www.millerwelds.com/resources/welding-resources

Nice little PDF books on basic overviews for each process.- if you can skip the pages and pages of safety
They had something called "TIG Handbook" 85 ish pages long PDF but only on the website chapter by chapter.


Lincoln has good info on their electrodes

Hello

Is there a thread that collects all the links provided ?

Some forums allow to "pin" threads so they are always at the top.


ABout LIncoln documentation, I was surprised to discover many guides are free, you can order them (paper version ) free of charge (even outside USA in some countries apparently)

Best regards

low hydrogen , by Lincoln :

https://www.google.fr/url?sa=t&rct=j&q= ... ghYt3Qlq2Q