The New “What did you do with your Z today” (with off topic replies) XXXIV

JLarson

Dealing with a strange issue that some of you guys may have seen before in manufacturing.

We're having trouble welding endcaps on a part. The endcaps are wire EDM'd. When the parts are tack welded, the tack weld is abruptly burning through, creating a crater or blowout. This is a seriously experienced welder who has done this job for years with no issues. Only change is that in the past we've used a punch, not a wire edm, to make the endcaps.

Any idea on whether or not the recast layer created by the wire edm would cause issues with weldability? Thinking about grit blasting the edge, ultrasonic cleaning it, and then trying the weld again.

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2014 370z Touring Sport Magma Red MT // BP Single Turbo 6467 // 63mm TB's // Z1 Ported Upper Mani // RJM Pedal // Zspeed Stage 3 Clutch // 526 WHP, 451 WTQ
2006 350z (Sold) // 1990 300zx (Sold) // 1985 300zx 2+2 (Sold)

madwi

Very possible there is scale buildup from the brass wire. Ultrasonic would be a good idea between the two operations anyway as it is submerged in dielectric oil in the edm machine.

*Edit* I lied, they use deionized water in the wire machines if I recall correctly.

JLarson

Correct, deionized water is used.

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2014 370z Touring Sport Magma Red MT // BP Single Turbo 6467 // 63mm TB's // Z1 Ported Upper Mani // RJM Pedal // Zspeed Stage 3 Clutch // 526 WHP, 451 WTQ
2006 350z (Sold) // 1990 300zx (Sold) // 1985 300zx 2+2 (Sold)

madwi

I am not a welder but If I had the material on hand I'd clean up the edges on one up real good and try it again.

BettyZ

I'm not a welder but I saved 6% on my car insurance by switching to AllState.

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'14 MB Nismo | Boost Lab 6870 1.32 AR 553 HP / 471 ft.-lbs.
Betty Mods

Zingston

Well... hmmm... all that savings actually kinda makes you a welder.

Rusty

On difficult material. We used a burr bit in die grinder, to clean up the weld area to shiney metal. A powered wire brush wouldn't clean well enough.

JL, what type of material you trying to weld?

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浪人 - 殺し屋
"The Difficult Anytime, The Impossible By Appointment Only"
http://www.the370z.com/members-370z-...o-journal.html

JLarson

.031 thick Hypernom per MIL-C-14411C Type 1. It's a high nickel (80%+) iron alloy used in magnetic shielding.

__________________
2014 370z Touring Sport Magma Red MT // BP Single Turbo 6467 // 63mm TB's // Z1 Ported Upper Mani // RJM Pedal // Zspeed Stage 3 Clutch // 526 WHP, 451 WTQ
2006 350z (Sold) // 1990 300zx (Sold) // 1985 300zx 2+2 (Sold)