What am I doing wrong?
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FTE Leadership Emeritus
Joined: May 2004
Posts: 18,787
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From: Melbourne, Aus
What am I doing wrong?
Ok,
I have the rotor shaft out of a 500kW motor... which is 4140.
To get a new rotor shaft made up is much dollars, and far too long (it has some intricate CNC work on it)
So, I need to weld it, re machine it and grind it.
I have some Ferrocraft 61 welding rods (link ) (unfortunately I don't have access to a TIG
), and I just cant get a weld started 
I have pre-heated the area..
What am I doing wrong?
I have the rotor shaft out of a 500kW motor... which is 4140.
To get a new rotor shaft made up is much dollars, and far too long (it has some intricate CNC work on it)
So, I need to weld it, re machine it and grind it.
I have some Ferrocraft 61 welding rods (link ) (unfortunately I don't have access to a TIG
), and I just cant get a weld started I have pre-heated the area..
What am I doing wrong?
Postmaster
Joined: Apr 2004
Posts: 2,654
Likes: 0
From: Bossier City, LA
Fred, lets start with the rods first. What the heck is a ferrite 61? I would weld it with 7018 if it were me, however a little more info might help too. What is the hardness of the shaft you are trying to weld?
Fleet Mechanic
Joined: Jul 2000
Posts: 1,493
Likes: 346
From: SE Iowa
The problem is 4140 is normally VERY difficult to weld. Do a quick google search on "welding 4140". Basically, you need to preheat to 450deg for at least 15 minutes. That's some off the tricky part because it will be hard to maintain that temp for 15min. Then use a low hydrogen rod like 7018 that has been baked dry. Next is the REALLY important part. You have to control the cooling. I want to say for several hours. I cant remeber exactly how long so do some searching. If it cools too quickly it will crack!
Myself, I would recommend against it.
Myself, I would recommend against it.
Postmaster
Joined: Apr 2004
Posts: 2,654
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From: Bossier City, LA
Originally Posted by FTE Fred
Ferrocraft 61 is a E7018 type electrode.
The shaft is basic unhardened 4140... which off the top of my head has a Rc of 40-44
The shaft is basic unhardened 4140... which off the top of my head has a Rc of 40-44
Fleet Mechanic
Joined: Jul 2000
Posts: 1,493
Likes: 346
From: SE Iowa
4140 has a hardness around RC32 (BHN 302). When its annealed, its MUCH softer...around RA56 (BHN 197). When its annealed, its readily weldable, then it can be heat treated back to the standard 4140 specs.
Fred, cant believe I didnt think of this before. Do you have a local heat treat business around that can anneal/heat treat it for you?
Fred, cant believe I didnt think of this before. Do you have a local heat treat business around that can anneal/heat treat it for you?
Fleet Mechanic
Joined: Jul 2000
Posts: 1,493
Likes: 346
From: SE Iowa
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FTE Leadership Emeritus
Joined: May 2004
Posts: 18,787
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From: Melbourne, Aus
I assume that 450deg is in Farenheit? (Sorry, I thought best to check!)
I had it preheated
I will put the rods in the oven too
On edit: I took the assumption it was in F - sorry, meant to post this a while ago.
As for the heat treater - we have an induction heater here...
I am waiting for it to cool now (am dropping the induction heater down slowly)
I had it preheated
I will put the rods in the oven too
On edit: I took the assumption it was in F - sorry, meant to post this a while ago.
As for the heat treater - we have an induction heater here...
I am waiting for it to cool now (am dropping the induction heater down slowly)
Last edited by BigF350; Feb 26, 2008 at 11:11 PM.
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Fleet Mechanic
Joined: Jul 2000
Posts: 1,493
Likes: 346
From: SE Iowa
Glad to hear all turned out for the best. Had I known you had an induction coil at your disposal, I wouldnt have been as concerned. Being able to control the cool down like that probably made all the difference.
P.S. I've at least started a materials write up. Whenever I get it finished, I'll post a copy for you to add to the tech sticky. These hours at work are killing me.
P.S. I've at least started a materials write up. Whenever I get it finished, I'll post a copy for you to add to the tech sticky. These hours at work are killing me.
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FTE Leadership Emeritus
Joined: May 2004
Posts: 18,787
Likes: 30
From: Melbourne, Aus
Originally Posted by stryder
Glad to hear all turned out for the best. Had I known you had an induction coil at your disposal, I wouldnt have been as concerned. Being able to control the cool down like that probably made all the difference.
P.S. I've at least started a materials write up. Whenever I get it finished, I'll post a copy for you to add to the tech sticky. These hours at work are killing me.
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