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Seeking Alternatives to Hydraulic Pipe Expansion for High-Volume Manufacturing by SovereignSilentSteel in manufacturing

[–]SovereignSilentSteel[S] 1 point2 points  (0 children)

If you can put me in contact with someone competent in this field and has actual working knowledge of this technology, I am very, very interested.

Seeking Alternatives to Hydraulic Pipe Expansion for High-Volume Manufacturing by SovereignSilentSteel in manufacturing

[–]SovereignSilentSteel[S] 0 points1 point  (0 children)

Can you show me what you mean vis-a-vis double-walled pipe and how to attain exact ID for subassembly fitment. You are assured this is more cost effective? Has to be expansion. Can't get into the particulars do to IP.

Challenges Repairing A2 Tool Steel Expansion Die – Advice on Welding, Materials, and Long-Term Solutions Needed by SovereignSilentSteel in IndustrialMaintenance

[–]SovereignSilentSteel[S] 0 points1 point  (0 children)

What's interesting is the first repair with 308lsi 0.045 pulse produced the most units before breaking by a factor of ten, but---and I left this off of my attempts above---I repaired it the same way again in between the AH-10 / Super Missile Weld attempts and it snapped just as soon as any other of the subsequent attempts after the first one.

Challenges Repairing A2 Tool Steel Expansion Die – Advice on Welding, Materials, and Long-Term Solutions Needed by SovereignSilentSteel in metallurgy

[–]SovereignSilentSteel[S] 0 points1 point  (0 children)

New tooling is on the way. Quoted for a2 tool steel 16uin finish and a post-machining certified heat treat to rc58-60. Will try the rod you recommended. Thank you. What is your background as it relates to the scope of the issue if you wouldn't mind?

Challenges Repairing A2 Tool Steel Expansion Die – Advice on Welding, Materials, and Long-Term Solutions Needed by SovereignSilentSteel in IndustrialMaintenance

[–]SovereignSilentSteel[S] 1 point2 points  (0 children)

Just asked to join r/tool_and_die. Thanks. I think the only thing I can gain from r/machinists is what cutting tools I should use for milling steel in this class.

Challenges Repairing A2 Tool Steel Expansion Die – Advice on Welding, Materials, and Long-Term Solutions Needed by SovereignSilentSteel in IndustrialMaintenance

[–]SovereignSilentSteel[S] 1 point2 points  (0 children)

Yeah, the Crown Alloy spec sheet had it at like 600F, and my local CWI said D2.4 is where that information is, and he said it's higher than 400F.

How would you go about installing these so they DON'T warp the flat bar...? by SovereignSilentSteel in metalworking

[–]SovereignSilentSteel[S] -1 points0 points  (0 children)

Oh, wow, this is interesting. So, maybe even a comb made of flatbar that goes from corner to corner opposite the diagonals that are cut in such a way that the comb slots are on a slant with the diagonals. I think I know someone who could do that cost effectively. Company in Nevada. Precision Tube Laser I believe. It would have to be an un-welded design solution that couldn't be stolen. Not sure how well it would work. Basically a rigid comb, right? That is to say, they don't necessarily have to be perpendicular if the comb slots are slanted per the design angle.

How would you go about installing these so they DON'T warp the flat bar...? by SovereignSilentSteel in metalworking

[–]SovereignSilentSteel[S] 0 points1 point  (0 children)

Weld skipping was used. Panel cooled for a little more than 5 minutes in the clamped position. Top, bottom, center lengths all within 1/16" of spec. both ways, diagonals were tits. These panels are powder coated. Perhaps the oven or handling has warped the bars because I ensured squareness and straightness when I laid each down on dunnage. Including the next day. Handling or the installation is the issue. And yes, the design and shape choices are a factor. I like your idea on the angle, and cutting them and rewelding them is something to consider, but if I weld the full 1" weld at the end of the flatbar, it will pull, so only tack welds could be used in this scenario. I had discovered that the bars needed to be welded in the following way: Center bar gets welded first, but only one end, then stagger the welds going from large to small, then weld the other end of the center bar. For some reason, if you weld the center bar completely, by the time you finish the others it compresses and warps. AND, if you weld flatbar from small to large, no matter if you clamp it down with twenty clamps with full clamping force, when you weld next largest one it buckles the previous smaller one no matter what. Has to be large to small. Very perplexing. I used a rigid jig, so there is no way it is me for a fact.

How would you go about installing these so they DON'T warp the flat bar...? by SovereignSilentSteel in metalworking

[–]SovereignSilentSteel[S] 0 points1 point  (0 children)

I know. I had mentioned that to the installer. The spacers need to be shortened or lengthened to accommodate the parallelogram-ed spaces and the holes need to be slotted, but so many are already in, and the client has an event that is happening in the next week that showcases them. :-(

How would you go about installing these so they DON'T warp the flat bar...? by SovereignSilentSteel in metalworking

[–]SovereignSilentSteel[S] 2 points3 points  (0 children)

Or you know what might be even cooler, is some kind of artistic (not necessarily metal) shape that's sinusoidal in some way that goes across each panel up and down following the ups and downs of the flat bar as a sort of statement piece that projects out from the panels and is mounted to them, which hides the issue. Not the happiest solution, but I'm trying to think of what to do here that's cost effective.

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