Welding Tips and Tricks

Hey all, I have a question that I have had about a dozen different answers to so far and yet no solid solutions to. I run an Aggregate plant in the northeast and am the operator maintenance and clean up crew. (thankless job, but i do love the high iron) I deal with AR 400 and 500 on a daily basis and have been told for a while that the only way to "stick it" to a36 is to use Chronatron 333 rod????? I know better but can't convince them that using a higher strength rod than necessary is the exact problem they are trying to remedy is caused by what they are using. I have always been taught to preheat and watch your heat on the interpass. 333 rod is designed for stud removal and dissimilar metals that heat sink differently according to the book I have. any advice would be wonderful as I am sick of my boss looking at me like I am crazy when I preheat and weld it 70-18 while our head Fabricator just boogers it together with the $45 a pound rod (mind you he's that just because they ran out of places to stick him when no one could take him anymore.)

Good lord...

Sounds like he's clinging to an idea someone planted in his head.

You don't need a filler any tougher than the base metals, and you sure don't need anything out of the ordinary to make those welds.

Personally, I'd look the site engineer in the eye, and tell him to get me a can of 8018 and a small rod-oven to keep 'em fresh, and I'll save a ton of money. You can argue the 80Kpsi more equals the hardness of the base, and time will prove you right. (Frankly, 7018 would do, just like you've been doing. You'll make more of an impression with your argument with 8018, though. It's human nature.)

Steve S

Thank you much for the Affirmation of what I was almost certain was the case. I just didn't want to look like the fool I knew he was! I am sure I will be back with more soon (probably would have been today but... he had the day off and all was well in the nice quiet shop)

Not too long ago I did a shutdown at an asphalt plant. We were relining the hoppers at the truck load-out, which suffer great heat and abrasion. The specified filler metal was 70- series flux-core (dual shield).

In the old lining, there was no difference in wear between the plates and the welds.

Steve S

Finally! A topic I have specific experience with! I used to do maintenance on an aggregate plant. When using AR plates I did all my joining with 70 series electrode, generally 7018. If I was especially concerned about abrasion in the area I would cap with a hard face electrode, but to be honest I don't think I ever saw a failure related to a weld eroding faster than the parent metal.

I like Otto's advice about 8018, though...it makes you sound all wizardy.

Have you ever had to join manganese alloys to steel? We used to have fits with it then we found a rod which I can't remember who made it, but it's trade name was Mangalloy that worked great for it, as long as you watched your heat to not embrittle the manganese. I was just curious what you used. We were a start-up and had a lot of trial and error learning.

Do any of the aggregate plants use 'Linatex' red rubber linings for erosion protection?
http://www.weirminerals.com/products__s ... natex.aspx

I'm not advertising the product, just curious if you've seen it out there and does it work?
I convinced the supplier to send me a sample for a hovercraft skirt. (for the ground contact patch.)

I can't speak for aggregates, but I've used Linatex in ethanol plants.

Abrasion wasn't a factor. We used 6" strips as flexible ducting for fabricated expansion joints. It was chosen for it's tolerance to thermal shock and vibration.

Steve S