Shaft build up

  1. I think I mentioned that one half on my shop is a machine shop. This is some of the work that we do together.... the combined trade really work well together.

    The piece is a solid 15.2 cm x 15.2 cm x 330.2 cm shaft that a series of paddles attaches to. As you'll see they let the bearing wear through wiping out the end.

    This took 3 half length passes and 3 full length passes to build up for maching, as well as the entire day. The first 2 passes were with .035 soild wire, short circuit transfer. On the 3rd I started to use a 1/16" dual shield wire in a spray transfer.... and the 3 full length passes were done with this as well. I went back to the .035 to put in the last 1/2" of weld on the end of the shaft... the spray transfer is way too hot to build the shoulder.

    Shaft chucked up in lathe
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    shaft chucked up in positioner
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    1st 1/2 pass
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    2nd 1/2 pass
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    3rd 1/2 pass
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    1st full pass
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    Checking temp... handy tool to have
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    Smoothed out the 1st pass... prep for 2nd
    [​IMG]

    continued in next post.......
     
  2. 2nd full pass
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    3rd full pass
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    fill out end woth .035 completed build up
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    Shaft machined to correct dimensions
    [​IMG]
    Thanks for looking...... :welder:
     
  3. How much wire did you go through to build something up that thick? And if you don't mind me asking, what temperature did you have it cool to before cleaning it up and doing the second pass?
     
  4. lexi Member

    Posts: 1,208
    paisley
    Lorenzo. There is a company just down the road from me that does exactly what you are doing there. Have watched them many a time. The shafts are big ones about 2ft in dia. Guy lays the metal in with an Arc the size of a walk in fridge. The rods are the thickest I`ve seen. It`s for North Sea Oil industry

    Alex
     
  5. Drains

    Drains Yeah, nah.

    Posts: 7,677
    Soggy Sefton, NZ
    Lorenzo - another fine job. We used to build up the weld for hubs for centrifugal fans with the job going round and round and a welder on each side of the turntable pouring it on. Always looked great after the machine shop had done their bit.

    I couldn't work out what the shaft was for - got the paddles bit... but it looks like a pretty high duty piece of kit. Once you've machined up the bearing surface, does it get case hardened or anything?

    Vaughnf, my missus is from Invercargill! If you went to Boys High, her old man might have taught you! (depending on your age of course)

    Lexi. I can't believe it - there's still a machine shop left in Glasgow. Thank god for that. There's almost none over this side any more.

    Si
     
  6. Hey Si...... the shaft is set up with some paddles and it is used to mix asphalt at an aggregate plate. The shaft didn't require any type of hardening.. but the plant has us turn up 5 new shafts as well.

    Machine shops like ours are becoming more scarce in the area, no one wnats to do this kind of work anymore..... I really feel that in the near future tradesmen like myself will become fewer and fewer inbetween. Eventually we'll be considered craftsmen because there won't be enough people doing this work to consider it a trade.... it will be a craft.... like the old stone cutters.
     
  7. I'm not sure now on the wire but there would be approx 130 linear feet of weld to do the build up.

    Running a girnder over the saft end actually hepls to cool the piece... so I would spend a few mins dressing it up with a flap disc..... the temp would probably get down to about 200* F

    The guy that runs the machine shop side is from the ship repair industry.... the horizontal boring machine you see in my grapple rebuild post, http://www.mig-welding.co.uk/forum/showthread.php?t=2039, is nothing compared to the equipment they had at the yard. The entire machine would have fit on the table of their machine.:laughing: I love seeing this big stuff getting worked on.
     
  8. lexi Member

    Posts: 1,208
    paisley
    Yeah there is still quite a few in Hillington. The one I spoke about was McNair Eng. I have a few contacts to get a loan of an odd tool for anything one off. Rolls Royce have just moved from Hillington To Inchinnan after maybe 40 yrs there. The guy who makes the special blades on Harrier jet engines stays across the road from me. That being said he aint never seen the finished engine product.

    Alex
     
  9. echo20 New Member

    Posts: 1
    UK Southampton
    Knowing what you're doing!!!

    I work for a company that specialise in this type of repair, you may well come a cropper if you haven't allowed for stress relief or heat affected zones matey. the composition of the material used may lend itself to the formation of martensites which cause brittleness, if enough torque is used the shaft may shear. rotating the shaft and welding spirally will reduce the distortion but knowledge of the material is essential, pre-heat and control of inter pass temperatures is crucial.
     
    Last edited: Jun 25, 2009
  10. Sparkey

    Sparkey still sitting in my corner of the forum

    Posts: 5,041
    France
    Not sure if you noticed but....this thread is 2 years old, matey...:whistle:

    ps: it's been a while lorenzo has been here so i don't think he's going to reply to your post...
     
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