welding 6mm steel to axles

[g1oves]

Hello , im in the middle of a little project designing and building a new suspension system for a 4x4 , iv done a lot searches and read a few posts on this forum and over seas with similar interests and it still baffles me when it comes down to penetration, im welding a selection of brackets in 6mm to 1/4 thick axle housings ,im currently using a Clarke mig 195te but it concerns me that I cant get the penetration I need to give me strength for off road driving, what worries me is i think I fell for the same b@%"$*%$ sales scam with Clarke welders like most others,when they tell you it can weld 7mm steel which it probably can but that doesn't take into account penetration , so my `Question, is my little mig really up for it and give me the results im after or is it time to move up the ladder or amps with a better bit of kit.

Also were can I get the acid testing kit colleges use for checking for penetration when they have cut through a weld?

many thanks gloves

 

[madkayaker]

Ok couple of issues here

The Clarke will weld 7mm in theory with lots of weld prep to reduce the true thickness of the parent metal. However in a fillet weld that's not going to help much as one peice will still be true thickness

Now the welding an axle issues. What is the axle made from all the ones I have messed about with (landrover) have been cast and they don't like welding at all.

Also is this vehicle going to be used on road would think it would need SVA testing with VOSA

 

[rtbcomp]

I think you'll find they're forged rather than cast. There's plenty of welding on Landy axles, the banjo cover and strengthening web (MOD vehicles) spring to mind.

 

[madkayaker]

You might be right there. The mod web though doesn't look welded on from what I remember. If it is forged welding would weaken it wold it not?

 

[g1oves]

the axles are off a land cruiser 80 series which look like steel sections welded together , and the vehicle will be for road use and will be sva tested , that's why its got to be bob on and for peace of mind, what amazes me is the welds that held the old brackets and links was a disgrace but I want it right.

 

[Bede]

A 195 amp mig should cope with adequate penetration.

Full power, not too fast a wire feed and a good clean, de-scaled welding surface should easily kill it. Provided your welding is half decent of course.

 

[langy]

Be careful how you weld axle cases as you will easily warp the tube