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Building up a worn shaft (spray welding)


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  #1  
Old 02-13-2008, 05:27:41 PM
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VicP VicP is offline
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Default Building up a worn shaft (spray welding)

I was referred to a small machine shop to spray weld a small shaft that needs building up a thou or two. A telephone enquiry said No, he would stick weld it, straighten it, turn it down etc whatever it needed at $50 or $60 sight unseen.

Well I have an 80 amp machine and not a very steady hand and a Myford lathe that can handle the crank. Am I over my head here ??? Its a 7/8 shaft and only about a 1-1/2" length next to the crank needs filling. Will I stress it and will it then break off? Do I run beads lengthwise or while turning it? What rod ? See the pic I would appreciate your advice. I wont be hurt if you say leave it alone ! Vic
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Old 02-13-2008, 07:12:53 PM
Ray Freeman Ray Freeman is offline
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Default Re: Build up worn shaft

The shaft is unlikely to be mild steel so welding it without knowing what it is could be risky. It will bend if you stick weld it and you will spend a bit of time getting it back nice and straight again.Thats why spraying is so suitable for jobs like that. If you do decide to weld it weld while turning it. Preheat the shaft before welding and use a 7016 or 7018 low hydrogen electrode. If the shaft is a cheap high tensile carbon steel like 1045 its risky. You could try putting a dob of weld on the end of the shaft and then machining it off. If you blunt a bit of high speed cutting steel getting it off, spray it.
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Old 02-13-2008, 07:23:26 PM
Tom Weatherford Tom Weatherford is offline
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Default Re: Build up worn shaft

Get it spray welded and ground to size.
That is you best bet.
Tom
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Old 02-13-2008, 10:11:51 PM
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Default Re: Build up worn shaft

Thanks Ray and Tom

I was afraid doing it with a stik has the potential to create more problems.

I am familiar with the term spray welding. Thinking its crankshaft rebuilders

that do it on journals with special machinery. How is it done ? Hot Cold ?

Sounds expensive. Vic
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Old 02-13-2008, 11:29:32 PM
Ron Weber Ron Weber is offline
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Default Re: Build up worn shaft

Why not grind it down to clean up and then pour new bearings?
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Old 02-14-2008, 12:13:10 AM
Ray Freeman Ray Freeman is offline
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Default Re: Build up worn shaft

Quote:
Originally Posted by vicp View Post
Thanks Ray and Tom

I was afraid doing it with a stik has the potential to create more problems.

I am familiar with the term spray welding. Thinking its crankshaft rebuilders

that do it on journals with special machinery. How is it done ? Hot Cold ?

Sounds expensive. Vic
Theres a few different processes. Some use powder through a Oxy Acetylene flame and the one I have a lot to do with is arc spraying where basically mig wire is converted to sparks and blasted on to the job with compressed air. They can spray almost any deposit from cast iron,stainless steel to white metal. With that process there isn't a problem with distortion.
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Old 02-14-2008, 01:08:43 AM
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Default Re: Building up a worn shaft (spray welding)

Ron Ray Thanks again for the info and suggestions I will make a few enquiries. This will help me determine which option to take thanks again

Vicp
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Old 02-16-2008, 10:24:50 AM
DTurner DTurner is offline
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Default Re: Building up a worn shaft (spray welding)

Possible to chrome plate it and regrind if its less than 5 to 10 thousands .
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Old 02-17-2008, 11:54:54 PM
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Default Re: Building up a worn shaft (spray welding)

Well I have considered turning the shaft all the way its full length with new
bearings to fit BUT then the flywheel on the bare end will need a thin bshg?? That may be difficult to make, fit and hold steady ??

Will have to check out the chroming suggestion and see what that would cost

Thanks again Vicp
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Old 03-02-2009, 05:48:32 AM
arkot arkot is offline
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Thumbs up Re: Building up a worn shaft (spray welding)

Since wear is only 2 thou on radius, chrome plating will be ideal if one off job can be done by the jobber shop. Then ground finishing to required dimension.

Fusible metal spray will be ideal. Powder which will give required hardness needs to be selected. There are 3 popular ranges -one giving 10-15 RC ( Fully machinable), 40RC ( Machinable with Tungsten Carbide tip tool on automatic lathes) and 55- 60RC ( can only be ground finished).

For this application the powder with high hardness will be suitable.

A spray torch, oxy-acytelene gas welding set with a good set of pressure gauges will be required.

Mechanically or Chemically clean the area to be sprayed.

Mount e 7/8" shaft on a vertical drilling m/c.

Set 5000 RPM to rotate the shaft.

Preheat the shaft worn out area with the spray torch to light Blue color.

Spray the powder on required area for 30 seconds.

Fuse the powder.

Take away the spray torch from the job and allow the shaft to rotate till it cools to room temperature.

You will have a distortion free job.

Grind finish the shaft to required dimension.
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Old 03-03-2009, 09:33:51 AM
mfman0 mfman0 is offline
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Default Re: Building up a worn shaft (spray welding)

vicp : just a suggestion from a new member here. would be very careful if this is a crankshaft using 7018 rods,YIKES. We do this kind of work daily & may be able to help you. Would need pics of shaft or actually see it But I am sure there is a safe way to repair it. What I would like to see done( if possible) is turn diameter down & heat shrink sleeve on to save weld distortion & risk of cracking from weld. We are just an hour away from you. PM me if you want to send some more details.
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