Welding Tricks! How to weld Steel to Cast
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- Опубліковано 5 лип 2024
- Here is a fun project! I show my tips and tricks when it comes to welding tabs, brackets, and most importantly , How to weld Steel plate to Cast steel.
Tools used..
Harris super Missile welding rod
www.airgas.com/product/Weldin...
Miller Multimatic 220 ac/dc multiprocess welder
www.millerwelds.com/equipment...
Hobart Nickel99 welding rod
www.hobartwelders.com/consuma...
Barnes 4wd super duty high steer kit
barnes4wd.com/products/weld-o...
keywords
fabrication
welding
tig welding
mig welding
dissimilar metals
barnes4wd
ford f250
super duty
welding tutorial
how to tig weld
dirt head shed
And with a straight face, "I made these shims from a beer can that I borrowed from a neighbor". Had me rolling.
I can’t believe it either
Dave has always had great one liners. One of my favorite things about him
Chicken lights!
Man, it's just nice to have a channel with good tech and a likable guy. So tired of all the in-your-face douchebags with videos titled "Extreme welding tricks, you won't believe what happens! Watch to the end to see me almost die!" This channel is a gem, no clickbait, just good stuff.
Thanks! Trying not to be a flash in the pan. Slow and steady wins the race… hopefully
@@thedirtheadshed Lots of us out there appreciate quality content by a decent guy. It's one of the few channels I recommend to my friends on a regular basis.
This is the dirst cideo ive come across from his channel. The name and these comments had me click sub.
Finally something good to watch on Friday night
Hope ya dig it
Completely agree!
Stay Tuned with Tony Angelo also gets Friday releases.
Felt like a Bob Ross. Awesome job Dave! The mellowness and humbleness you bring are great to watch :)
I’ve been called the Bob Ross of Bondo.. I’m ok with it
Just a little tech behind the tig rod choice and cooling down. At the core is a difference in thermal expansion rates. Because the two different materials expand at different rates for a given temperature increase, it is in your best interest to preheat it and use a rod with a large elongation and slowly cool it. The preheating makes it so the weld does not get stretched apart as it heats up, it only gets compressed when it cools. The rod has to have enough elongation such that it can stretch enough to accommodate the two materials shrinking at different rates when it’s cooled down or else it will crack. And the slow cooling has to do with the strength of the material after it’s been heated up. The intent is to cool it slow enough that the materials can equilibrate in a uniform manner. If you cool it too fast you can get localized cooling which causes nonuniform stresses which can cause cracks. Thanks for the how to!
Good explanation right there! Thanks for the response
I was always go to 450 degrees pre welding and reheat to 450 after welding is done then peen the weld with a welding hammer while it’s hot then wrap it in a welding blanket. It’s always worked well for me. Great video Dave!
You get after it!
Great tutorial Dave.
I do basically the same. But when I am building axles not yet mounted, I use a big propane weed burner for pre and post heat
Thing about Tig is it's super direct an fast. In some cases especially with dirty cast and mild steel you might actually be better off putting more of a puddle? Give it time yo burn off some impurities? Thus why your running 190amp?
Exactly. If it is a mounted part use a blanket, if it is a free part bury it in sand. 30 yrs welding all kinda shit and that is the approved procedure according to the lincoln big book of welding if you cannot afford a heat table or oven. never had a failure.
I’m just glad I’m not the only one that works out of one tiny corner of a big table full of stuff! Another great video Dave! Will be doing this on my 60 soon
Never enough room!
Back in the nineties, we used super missile stick rod… you could weld duck poop to a granite rock with that stuff… wicked expensive, though, if I recall…
Yep! It’s still expensive
I'll be using that jack bolt trick in the future for sure!
It’s definitely a good one!
Good job.... the Bob Ross of welding! Start saying "Happy little weld."
Next time!
Someone played a joke on me and turned down my regulator and I spent a half hour figuring out why I was welding like shit, ha ha ha, well done Dave. The beer can comment for the shims was hilarious as well.
I’m glad I caught it as quick as I did
70/18 or 80/18. With pre heat will weld it just fine as well and be just as strong. Done it many times
I need to use my stick welder more often
After researching it to death I went with 70/18 to weld the truss and C-gussets on my JK Dana 30. That was almost 3 years ago and it's holding up great.
Dude you couldn’t suck at welding on your worst day. You’re a pro man 🤘🏻
I appreciate that!
I have that same welder. It’s been great for the little things I use it for. I need to really put it to work and build a car hauler though👍
Thanks for sharing!
“Beer can from a neighbor “ is why we love Dave!
Ya caught me
Great Video! I like to use the welding blanket to rest my hands on while welding. It helps keep heat in the parts and keeps me from saying YEEEEEOOOOOW That's hot!
I need to get some of those fancy gloves I keep seeing on instagram
I'm actually just getting into welding so this is very informative. Unfortunately I only have a crappy stick welder to start but hey it's something
Get to be good with the stick welder and all the other types will be easy
I'll be honest man. I only fabricate stuff to save money in my trucking business and around the farm. I started with just a buzz box stick welder. I still will usually grab it over my mig welder. It is a great asset to have. Also if you ever need to you can crank it all the way up and use it to cut materials as well. It definitely isn't a clean cut or anything but I have some it before when my cutting torch ran out of gas. Best of luck to ya.
Just learning welding and fab. Would love more content like this!
It’ll be scattered in here and there
Really dig the fabrication/ welding tutorials that you do. Keep them coming!
Right on. Thanks
Good stuff Dave, had my morning coffee watching this one. Have a good weekend.
You too. Thanks for watching.. and commenting
Here’s my two cents. Push weld a root weld especially on quarter inch or thinner. Do a cover pass weld with basically 90° on the gun. You’re right about the sparks and if it is Cast steel give it some preheat.
When Cast steel is thin, like say, a pipe coupling, you can use the root weld as the
preheat.
37 years experience ⚡️🤷🏻♂️
That’s good advice
21:54 that is an awesome idea, using the welding blanket..
Thanks. Quick and easy!
I've got some 035 flux core stainless wire I originally got for a stainless handrail job that I also used to weld mild steel to turbo, So if anyone is not set up for tig or stick they sell stainless mig wire too.
Yep! Good feedback
56 years old and just started welding again. Last time I did I was around 20 maybe 22 & it was stick. Great to see this now. Perfect timing. Excited to start doing lots more welding and any tip's or trick's is very helpful. Thank's Dave.... Always learn something watching You. 🤟😎
I appreciate that. Keep having fun in the shop
Missile rod is great, only stick welded with it, but it works. Nice looking job, always enjoying the videos. First time I got some 40 years ago, the salesman welded a file to an engine block to prove the point.
That’s a pretty cool demonstration
Fun video. As an old welder myself,I enjoyed that. I got to use "nickalloy" welding rods for a similar job once. Welding a huge cast sprocket that was cracked. Ground the crack out into a V, and welded it up. Took almost 50 pounds of those rods, and almost a week at 8 hours a day..lol. pre-heating after every pass. Weld looked like chrome when I was finished..lol.
That sounds like a big job!
It was a sprocket on a coal unloader along the Ohio River, at a power plant. It was used to dig coal from a coal barge, it was probably over 15" thick, 8 ft tall. Big dude. Funny part, I changed the same sprocket 2 years later during a big planned maintenance shutdown..lol
Thanks, Dave!
I’ve done a little cast to steel fabrication in the past. And yes, made mistakes in the beginning.
It’s so cool, that’s you helping everyone become more proficient .
Thanks. I still have a lot to learn as well
@@thedirtheadshed you are doing great, don’t sell yourself short!
Everything I see you fabricate is looks more than strong enough for the task. Along with enough style . To make us all motivated to do our best ! That is what keeps us coming back to your channel for more!
Thanks
Haha, glad I waited to comment, thought you were going to mig weld that to cast steel. Was going to let you know about Super Missile rod from Harris. Great stuff for what you are doing. They have the missile rod in stick form also, better than normal nickel rod.
Yep! The stick version kept showing up when I was trying to put the link in the description
Where do you get the super missile rod from?
Good thing your neighbor had that beer can to lend ya……
Sshhhh…. It was mine!
great video, Dave! ...it makes me feel better when you say, "ok, don't suck at welding today". You are a much better fabricator than me and i have the same conversations with myself. :) love your projects, keep up the good work!
Thanks! Keep practicing! It’s definitely fun to get better at this stuff
People start subscribeing more! Dave is freaking great and I wana be able to keep watching him!!
This guy speaks the truth!👆👆
@thedirtheadshed Hell yeah Dave!!
Glad I found your channel Dave. I've been watching Fred's channel for a while now. I still watch reruns of Dirt Everyday on MT. I miss your shows. You rock! 🤟
Hey! Thanks for the support! I’m over here cranking away on projects and stuff
That jack-bolt is a great trick!
Thanks. I use them a lot
Another good one Dave. Tomorrow I’m gonna start making shims so you don’t have to bother your neighbor.
Hahah! I’ll probably make a few myself..
Did this a few months ago. The way i heard Ian explain it was mig was what hed done before with no extra preheating. There has to be multiple passes to fill the gap. He explained the first pass is the preheat step for the cast steel knuckle. I could be crazy and mis-remembering what he said. When i welded my truss to the pumkin of my D60, i preheated to around 300 and peaned after welding with a mig turned up hot.
Ian knows his stuff. He’s a good resource
I know how involved cast iron is, but cast steel I wouldnt ever known there was an issue with it. I made a custom steering bracket off my k30 knuckle, just heated it enough to get good penetration, welded it and let it sit. Cast iron I always do the pre/post heat and wrap with peening
It’s definitely not as finicky. But I’ve seen plenty of mig welded tubes to center chunks break still
I flux core'd my steering knuckles and have wheeled for 5 years without issue, i did all the pre and post heat stuff
Good work! Make it happen
Awesome work! Staying positive while welding on the internet requires stones! Make it look so easy i might give it a go
The internet is a rough place to weld for sure! So many experts out there ready to tear you apart
Getting learnt with Dave. I’m now 💯 more smarter than I was a few minutes ago!
Well that’s good!
Another great video Dave. Keep it up. I appreciate the info on the stick welding as we all don't have the fancy stuff.
I need to break out the stick welder on this machine and keep practicing
The shim method is definitely better than just welding as-is and allowing it to warp out of control. However, instead of using the actual hiems in place, which can result in them being heated up (melting the teflon in the joint and ruining them) or them getting covered in weld bb's, a more ideal way would be to cut some heavy-wall tube that has the same ID as the hiems, cutting that tube to be a few thousandths larger than the overall height of the hiem joint spacers. In my shop, I actually machined a few pieces of tubing to the common hiem sizes that are used in what I'm welding. Then I can use them over and over again, and they take up less space than the hiems do, allowing me get the welder in where I otherwise wouldn't be able to with the hiem in place.
That is definitely ideal. I don’t have any heavy wall tube. Or a lathe to cut and face it perfectly right now
Hey Dave talking celcius pre heat to 200 degrees. Once you get to 250 degrees the cast steel can become brittle.
If the casting was iron you’d have a lot of black graphite dust which has its own particular smell. 👍
Keep up the great content.
That is hot!!
I always preferred stick welding with 7018, when welding cast steel to plate steel, it always seemed to have better strength and penetration.
I need to use that process more. I’m out of practice
That was a great video, thanks for the tips and keep em coming, please. Always good to learn new things.
Glad you enjoyed it!
Good job Dave ! Looks awesome!
Thank you
As always I enjoy your videos, I used to work at a company where we built VW engines to power portable sawmills, we added extensions to the end of the crankshafts, and ran a pulley off on side. It worked great but we had the process down to a science, big oven that held 25 cranks and a lath like fixture that held the crankshafts for welding. It was pretty crazy, heat and cleanliness are the keys, keep up the great work Dave!
That’s pretty awesome! I’m sure it was cool seeing them out getting used
@@thedirtheadshed It was, I really enjoyed talking to all the old timers who where using them, I really learned a lot working there and seeing all of the aspects of production and assembly, I even had a patent in my name for designing a saw mounted tooth sharpener. Good times back then, I’m now in the construction trade, bidding and managing architectural sheet metal here in Portland OR.
Awesome job Dave!
Thank you!
Cast steel to plate steel I've never had an issue with a weld when using mig with 75/25 gas as long as I preheated the cast material around 250⁰F or above and cooled it slow with a blanket. If you have lots of weld area like on cgussets, or truss to diff center section, when you rip your welds right after preheat you will keep the cast base material hot during the whole process. Usually I end up hotter temps after welding (400-500⁰+) then my preheat team of 250⁰F. Also when I mean preheat 250⁰, I mean the whole base material is that hot evenly throughout. If you're only heating up a small section of a bigger piece of cast, always run preheat hotter.
Cast iron is definitely more tricky. I use the drill trick to tell iron vs steel. Cast steel shaves and cast iron drills like dust.
I know everyone says don't mig the cast steel and I like stick welding a lot, but personally I've never had good luck with the cast rods. I've tried a bunch on a junk axle housing I had laying around before I scrapped it. I had better luck welding with mig, now I've been running everything axle/suspension wise migged for years, axle tubes and truss welding to center section, and c-gussets etc. And no failures so far with mig welds.
If I did a steering component like a knuckle maybe I would be more paranoid about using mig. Never used tig, but maybe I'll have to invest big $ to try to do more aluminum and try out that super rod for cast. If I can ever learn the harder welding style of tig haha.
Great video as usual Dave!
Thanks so much. Good advice on the drill spirals or dust. I’ll give it a try
Great video. Pre heating and post heating was a good idea, hope it holds up for you.
It should be good. If not I will let y’all know
Excellent work! Thanks for talking us through the tools and techniques!
Thanks for watching!
Great video as usual Dave. I don't have any welding equipment, but I still enjoy a good educational video like this, good tips and tricks to keep in the back pocket in case I am ever able to get a cheap welder at home.
Right on. I appreciate the support
Good tips Dave! Thanks 👍🏼
Thanks for watching!
We were welding cast iron headers on big trucks 40 years ago well that was until we started welding and bending steel pipe.
Always adapting!
Perfect opportunity to use the Induction Innovation Venop HP induction heater, with the flexible coil.
Not sure if that would work with it broke off at head
@thedirtheadshed Apologies. I didn't give enough context around my idea for the tool. Wrap the coil through the bearing race, around the outside of the cast steel. In the area where the weld would be.
Regardless, glad to see you back at it, after Dirt Everyday.
Even though welding was part of my job for twenty years, I never considered myself a welder. There's just so much I wasn't familiar with. case in point. Good work and as always thanks for sharing.
Same here. As a car builder or fabricator, welding is like 10 percent of the job it seems
your channel is very good! Greetings from Venezuela, I hope I can visit your workshop one day!!!
Thanks so much for watching. It’s awesome hearing where everyone is from
As always, a pleasure to watch your work. Thank you.
Thanks again. It was a fun one
Dave - another awesome tech video. These are my favorite, so humble. Keep up the great work!
Glad you like them!
Great video as always Dave
Thanks so much
You’re doing an awesome job with UA-cam!
Thanks! It’s a hustle! But I’m enjoying it
I love the learning channels! Been welding a long time, mostly mig and stick but a couple years ago I bought a nice Prime tig welder….havent had many opportunities to use it but videos like this help a lot!
Glad you’re digging the channel. Time to get some rig time in!
Thanks for sharing your knowledge and experience! I always learn something from your videos. I have never welded cast to steel myself but I remember watching my grandfather do it and I believe he was using those same nickel rods you showed. I need to try it out myself
The nickel99 rod is great. You can fix all kinds of things with it
Thanks for the tech tips. I enjoy learning while watching your videos.
Thanks for watching them
Could you maybe do a video on how to setup a welder for different materials? I know there's probably tons, but I love your content.
I will trickle that information in here and there for sure
A really good way to cool the part is use silica sand. It has to be VERY dry. Get big enough for the work with room around it. Put some of the sand in container. Once you finish welding the piece place in the sand and pour more on top covering the work.
Main things I was taught by very knowledgeable engineer at a heat treating plant. DRY SAND and make sure work is well covered.
It will cool slowly and evenly.
As far as grinding to find type of steel. That’s called a spark test. I worked for a tool steel supplier for years. That’s how you can differentiate between all types of steel, tool steel, cast steel/iron etc.
it’s not only the color but also the size and amount of sparks.
Good info. Thanks
I love my Furick Jazzy 10. My favorite cup. I'm definitely going to have to remember about that super missile rod.
He makes great welding accessories
good job Dave! love watching your fab skills
Thanks for continuing to support the channel dude!
Man, this came out just in time, getting ready to do the same brackets from Barnes on a front 60 for the XJ along with a truss.
Nice! That will be a fun project
11:16 Typical preheat temperatures are 700º-1200º F. Don't heat over 1450ºF since that will put the material into the critical temperature range and cause it to warp where the metal is thinnest.
I have heard as low as wave a propane torch for 30 seconds, and as much as 1200 degree. So far you’re the hottest
@@thedirtheadshed I come from a long line of millwrights and metal workers. I've been welding for 40 something years, although not a ticketed welder. My uncle Brian started the only dedicated Pipeline welding school in the world, and ran the 2nd largest pipe welding /fab company in Canada.
I've welded a lot of Cast steel in his shop (as a 4x4er)
love your videos like this
Thanks! More to come
Your welds look good man
Thank you
Looking great, thanks for sharing your knowledge!
Thanks for watching!
Jackbolt is a great tip.
I use em all the time!
Gorgeous welds, IMO. Thanks!
Thanks so much!
Agreed! It’s fun to watch someone do something they’re really good at!
Great video! I have some axle fab work I am planning for, and this definitely clarifies some of my questions.
Right on, best of luck
Dude!! Great video!!! Thanks for heads up on the different wire!!! Thanks ✌️
Thanks for watching and commenting. It helps me figure out what videos make
Great work🙌
Thanks!
Now i have an excuse to buy a tig welder! Thanks for the informational videos, i especially enjoy the fab vids!
Thanks! I support this action
That’s very cool too watch. We tig welded my rear sterling tubes too the diff. Man it makes me want my own tig welder.
Good idea on a sterling!
Great video, thank you!
Glad you liked it!
This has to be the best video on this process I've seen. Hopefully I get to use some of these tricks doing my cut and turned TTB!
I want to build a ttb rig too
@@thedirtheadshed That would be interesting. It would be cool to see how you configure the TTB axle and suspension. Cheers.
The slow cool is excellent! In the hillbilly shop that I work, they often have no patience and take things out to the water faucet. I’ve been trying to wean them to the air hose blow job for cooling.⚙️🤪
Newbs
Hi Dave. This was a timely video for me. I am building a tube buggy and I will be starting the 14-bolt and Dana 60 axles soon. It will have a front and rear steer. I enjoyed it and very educational. Thanks
Good luck with the new build!
Thanks so much. Keep those videos coming. I got into this from watching dirt every day. 71 years young. Thanks again.@@thedirtheadshed
I just picked up a bench top drill press for my shop. I plan on building a stand with wheels so I can move it out of the way when not in use. I have everything I need in order to tig weld the stand (except a way to sharpen the Tungsten) and I have about 10 minutes experience in that process, so I figured it would be a good starter project to actually learn tig.
I put the tungsten in a cordless drill and spin it on my angle grinder or chop saw wheel
Welding to cast steel is different the cast iron.
With cast steel I just might it and hit it with a small propane torch for about 30 seconds and done. I've done well over 100 knuckles like this and have not had a failure yet.
Cool.
How cool! Looks awesome
Thank you
I have that same welder! I traded it for my new 252 Miller wire feed. It's a fantastic machine
They are so good and versatile
love tech info like this!
Glad you enjoyed it!
thank you for giving us the benefit of your knowledge.
No sweat! I enjoy passing it on. Even if it’s not perfect
Great job. Really appreciate the education!
Thanks for watching!
Haha. I am in the middle of doing this. All alloy reverse stick rod is my go too. It makes welding cast a breeze
I’ll check it out
Great show!!!!
Thank you
I've welded cast to steel plate with stainless steel rod , works great.
Right on!
Ductile iron is what I believe those knuckles are made of. Same preheating and slow cooling process though.
I’d like to know the all of it is. Always questioned if the center diff chunk is the same or different
Ductile iron is common on castings that see vibration as it is less brittle and can take some forces without cracking vs cast steel. Suspensions, engines parts also big machinery components are typically ductile
Excellent work my man. Be careful running so close to your ground so you don't become one with your current.
Is that a thing?
@@thedirtheadshed If you become a better path to your ground than your work is. Sweaty arm hits that ground and hello.
I am a welder by trade you did great
For all you home guys if all you got is a mig welder go to the weld store ask for a 2lb roll of dual shield mig wire
Dual shield will weld that just fine
Awesomeness. Thank you.
Glad you enjoyed the video
Trick Piece .. great info !
Glad you liked it!
My favorite type of video right here fab knowledge by one of the best
Glad you liked it. Helps me know what people want to see
Great info!
Glad it was helpful!