- Jun 18, 2020
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Another way of making a semi-torus is with pie-cut sections.
The individual cells don't need to be perfect sections of a torus.
A fitting pattern would be a good idea, and panel-beat/ adjust so that it fits in the pattern recess.
Just a few comments both 2024 and 7075 aluminum alloys are realy not weld able by small TIG. Welders the weld will crack as it cools or in use there are alloys in each general catagoryvyhat are much easier to weld . I’ve been into TIG welding since the 60’s both at home and in the shop . I have a square wave welder that I’ve welded some rather big stuff far beyond the machine general rating carefull preheating and cooling makes it so you don’t need super powerfull machine to heat the weld area. I use a backnpurge with a separate regulator as well as a cup flow tester so I know exactly what file I’m getting all the time . Welding 3/8” aluminum is tough without controlled ore heat with smaller machines . You really need good experience to do this the average home welder is out of the game here if you can’t make a near perfect weld n lighter material you will simply put “fail” when attempting larger thickness regardless of material contrary to various videos it’s not an easy learn instantly process . When you add the new additions such as pulse and various power slopes you have to understand why these have been offered. Why were these not created years ago? That’s because the talented people were able to see understand what was needed then just the machines as needed. Of course the foot pedal helped this and experienced TIGwelders will use these effectively with the modern machines to refine the process .
You seldom will fine an old school person that will take the time to really do a “pro” job on hobby parts not even counting the costs . 20 years ago I worked part time in a race car fab shop as a retired person just trying to be productive . I was paid $100 per hour for my services . So it can be a well paying job if you know the process well. I was tasked to teach some of the shop people but none could do the home work let alone the real work. Cleaning the parts is essential to correct welds . Knowing what the material is is vital knowing what can be welded and how to prepare is too . It’s not like welding a rusted hulk out in the field . Gob something lik wel dwarf on a joint and hoping for the best is not TIG welding
I can see this dyno system evolving into a cnc machined series of parts . In order to make it all fit properly I YHINK some real cad work is necessary then maybe so 3 d printed parts to see how it works with low power “proof of concept” we called it in engineering . When it comes to cost analysis. Think an electrical partial clutch may bea better idea. Costing more to start with but haveing better measuring capabilities .
I was thinking of getting a tig welder to do up to 3/8 thick.
You really need 300A for that, but 250A is about as far as I can go on 230V AC, 10A, 50 hz.
I really need to find out more about tig welding aluminium.
Possibly it needs to be dc-inverter, then a high/low pulse or "clearing" pulse applied over that.
Does anyone have details on the aluminium-tig process?
There are some really good YouTube videos of a guy who builds smallish motorbike engines out of parts.
- besides Allen Millyard-
And he has got quite good flange buildup.
It doesn't show how he did this, but I would presume tig rather than mig.
This has around 3/8 thickness, and a weld cross-section of over half an inch.
This would need a lot of weld length, and would have to be done in many stages, from micro-tacks on up,
with substantial cool-down periods.