stuweep
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Afternoon all,
I've made the rookie mistake of letting my boss know I "can" weld.
So he's asked me to redesign a joint for a cable end and I'm a bit stumped to be honest.
The joint is a spiral wrapped stainless steel cable conduit fixed to a stainless steel insert, with a nut that slides over the end. The idea being that the conduit cannot be pulled off the insert, and the nut stops the insert being pulled out of the connector; simplified sketch below (conduit diameter 8mm).
The joint doesn't need to be air tight, the cable just carries electrical wires.
So the sketch is my initial design, where the insert has a receiving counterbore for the conduit so slide into, and I'd weld around the end of the insert using a rotary table with the machine (Rtech Tig 210 AC/DC) on pulse mode.
The problem that I've come to realise is that the conduit is so thin that I can blow a hole in it with just 3A.
I initially picked up some silicon bronze "Tig" brazing rods to try, but they turned out to be for gas brazing so they're going back. Besides, I don't think I could get them to puddle before the conduit melts through using the Tig torch.
I can't change the conduit or the nut, only the insert can be modified.
So my question is, what would you do?
Some thoughts floating around in my head:
(also just realised this thread is in the wrong place, apologies)
I've made the rookie mistake of letting my boss know I "can" weld.
So he's asked me to redesign a joint for a cable end and I'm a bit stumped to be honest.
The joint is a spiral wrapped stainless steel cable conduit fixed to a stainless steel insert, with a nut that slides over the end. The idea being that the conduit cannot be pulled off the insert, and the nut stops the insert being pulled out of the connector; simplified sketch below (conduit diameter 8mm).
The joint doesn't need to be air tight, the cable just carries electrical wires.
So the sketch is my initial design, where the insert has a receiving counterbore for the conduit so slide into, and I'd weld around the end of the insert using a rotary table with the machine (Rtech Tig 210 AC/DC) on pulse mode.
The problem that I've come to realise is that the conduit is so thin that I can blow a hole in it with just 3A.
I initially picked up some silicon bronze "Tig" brazing rods to try, but they turned out to be for gas brazing so they're going back. Besides, I don't think I could get them to puddle before the conduit melts through using the Tig torch.
I can't change the conduit or the nut, only the insert can be modified.
So my question is, what would you do?
Some thoughts floating around in my head:
- Don't send the rods back and try using gas brazing. I worry the flux would be troublesome though.
- Go for some kind of crimped design instead of welded. But the nut still has to slide over it.
- Have the insert cross drilled in several positions and plug weld to the conduit using a jewellery spot welder we have.
(also just realised this thread is in the wrong place, apologies)