D.wilson94
Member
- Messages
- 230
- Location
- Middlesbrough
Anyone ever worked or tested out for catapillar? My friend said he tested out there 10mm weld ..he failed because his weld was 11mm ,are they that strict
- Thread starter D.wilson94
- Start date
Parm
Respect The Sound System
- Messages
- 17,967
- Location
- Towcester
Looking at your location, I know exactly the factory you mean.
Done a lot of consultancy work for Cat at Desford, Stockton, Peterlee and Poland
They are proper strict and push for high standards as the competition is tough with the stuff they produce in the UK
D.wilson94
Member
- Messages
- 230
- Location
- Middlesbrough
I appreciate that but failing someone for a weld 1mm too big is strict ,i was just curious
Pete.
Member
- Messages
- 14,781
- Location
- Kent, UK
Quite right too because they are put under a lot of strain in use. We trialled a new model of small demo machine from a new manufacturer (can't name them) and the welding on the main arm soon started to crack along the toes. When it eventually failed, it actually split like a banana skin whilst I was using it. They got all indignant and claimed that I 'must have been abusing it' but sent a replacement arm off another machine which only had a few hours on it. Myself and the fitter un-wrapped it as soon as the courier dropped it off and that one was already starting to split.
10% over-sized. It's quite a lot IMHO.
10% over-sized. It's quite a lot IMHO.
D.wilson94
Member
- Messages
- 230
- Location
- Middlesbrough
Must of been pretty bad welds (i dont mean in appearence) i never really thaught 1mm would make much difference but i suppose you learn ,thanks for response
D.wilson94
Member
- Messages
- 230
- Location
- Middlesbrough
I been practicing vertical welds at work ,think im getting there
D.wilson94
Member
- Messages
- 230
- Location
- Middlesbrough
Parm
Respect The Sound System
- Messages
- 17,967
- Location
- Towcester
They look ok to me, but I’m the wrong person to evaluate those. Despite this being a welding forum I can’t weld. I can stick metal together with an electric process, excellent with a grinder
Kayos
Gone......
- Messages
- 9,422
- Location
- Yorkshire
Exactly my thoughts welding the Disco, my welding is rubbish but my grinding and seam sealing is second to none
Parm
Respect The Sound System
- Messages
- 17,967
- Location
- Towcester
I reckon we should ask the mods to have a grinding section on here
Shox Dr
Chief Engineer to Carlos Fandango
- Messages
- 18,008
- Location
- East Yorkshire
Thats a lot of wire gas, and labour time lost
pedrobedro
Man at Matalan
- Messages
- 13,069
- Location
- CX near Chesterfield
Stop it now please, if you want to go on Grindr just get the phone app
I read that Caterpillar used agency workers and trained them before they went on the production line.
Brad93
Member
- Messages
- 19,023
- Location
- Essex, United Kingdom
Not only is there a economic factor involved with making welds outside of specification, there is a mechanical one too.
A larger weld induces more stress into a weldment. As said, 10m of weld, with an extra 1mm in leg length could cause unplanned distortion or excess internal stresses, which then gives a greater propensity to cracking phenomena. Not only that but the heat input from an 11mm fillet is higher than a 10mm fillet which can have serious implications on high strength, RQT steel, in terms of both toughness and strength.
A 10mm fillet most likely requires three passes. It isn't as easy as you think to get that leg length bang on. Not just that, they will be looking at throat thickness too.
A larger weld induces more stress into a weldment. As said, 10m of weld, with an extra 1mm in leg length could cause unplanned distortion or excess internal stresses, which then gives a greater propensity to cracking phenomena. Not only that but the heat input from an 11mm fillet is higher than a 10mm fillet which can have serious implications on high strength, RQT steel, in terms of both toughness and strength.
A 10mm fillet most likely requires three passes. It isn't as easy as you think to get that leg length bang on. Not just that, they will be looking at throat thickness too.
Brad93
Member
- Messages
- 19,023
- Location
- Essex, United Kingdom
Now I can’t find the rest of this sample it probably got sent out to a customer.
But I done this on a Rebel. So nothing fancy.
6mm leg vertical fillet. Bit thick in the throat I will admit but it had plenty of fusion.
If you look at the toes on your weld they’re far too inconsistent in length.
That gappy appearance will create stress risers.
But I done this on a Rebel. So nothing fancy.
6mm leg vertical fillet. Bit thick in the throat I will admit but it had plenty of fusion.
If you look at the toes on your weld they’re far too inconsistent in length.
That gappy appearance will create stress risers.
Richard.
Member
- Messages
- 18,344
- Location
- Cambridgeshire
It’s not a lot.
+\- 1mm on the leg is an acceptable tolerance even by the most stringent inspectors.
It’s also more to do with stress risers than extra volume of weld metal deposit.
21% it doesn’t work like that either. Which is why you get throat gages as well as leg gages because the 2 don’t go hand in hand mathematically
Process position and settings can make a weld with a larger leg have less volume than a smaller one. It can be convex or concave depending on loads of stuff
There has to be a tolerance on leg length on manual processes for obvious reasons we ain’t robots. 1mm is the norm and certainly not a lot.
eLuSiVeMiTe
Member
- Messages
- 16,441
- Location
- ......
Could be a lot of other factors that cost him the test. Could be a simple as they didnt like his attitude and picked faults to cross him off the list. We are all selective in our tales to mates.
Maybe they were not happy with the visual appearance of the weld but could not fail it on that and had to fall back on failing it on leg length, usually I’d give a guy a second shot at it unless it was a total pig’s ear!
Richard.
Member
- Messages
- 18,344
- Location
- Cambridgeshire
These sound way more realistic than 1mm of extra leg being the cause.
The leg was probably the reason given but like I say a leg variance of 1mm for a 10mm weld for a manual process is quite normal.
Bigger or smaller than 1mm then your falling out side of usual* acceptance levels
*I say usual because at the end of the day the welding engineer will probably put that acceptance level together and he may say 0.5mm he may say 3mm he may 10%
If your hitting 9-10 or 10-11 consistently and manually on a 10mm design I’d pass it off on size with out a problem.
