Help Stop Wasting of Student Welding Materials
Help Stop Wasting of Student Welding Materials
(OP)
We use a massive amount of material teaching our welders GTAW welding aon 1" NPS Carbon Steel Socket Welds and Also for Monel 400 NICU Socket Welds. We cut the pipe from the welds to reuse the pipe, but we are told that we must cut one inch away from the welds because the hardened metal from welding would damage the blades in our band DoALL Band Saw (Model C-916M).
Is there away we can treat the metal through some heat treat ment process so that the welded metal will not damage the band saw blades?
Is there an special band saw blades that would not wear- if the blades break or wear to fast it would not be time or cost efficent compared to the price we save on material or would it?
We would like to cut the welds right at the socket couplings so that we can reuse the sockets also.
I am looking for several sugestions to help save us money. Each Monel Socket costs over $100 a piece.
I am open to any suggestions for our welding students.
(See Attachment)
Is there away we can treat the metal through some heat treat ment process so that the welded metal will not damage the band saw blades?
Is there an special band saw blades that would not wear- if the blades break or wear to fast it would not be time or cost efficent compared to the price we save on material or would it?
We would like to cut the welds right at the socket couplings so that we can reuse the sockets also.
I am looking for several sugestions to help save us money. Each Monel Socket costs over $100 a piece.
I am open to any suggestions for our welding students.
(See Attachment)





RE: Help Stop Wasting of Student Welding Materials
Does Monel pose a problem for cutting,use a coarse blade perhaps,it will cut faster. For steel weldments,you may anneal the pieces before cutting on a DoAll.
_____________________________________
"The richer we have become materially, the poorer we have become morally and spiritually." Martin Luther King Jr
RE: Help Stop Wasting of Student Welding Materials
How would I anneal them- please explain the procedure you would use?
RE: Help Stop Wasting of Student Welding Materials
With a little experience you can tell if the welder is proficient by checking his first pass. have found over the years that there are some very good welders that can't make a satisfactory socket weld.
You can make test coupons from Monel bar bored out to size instead of using actual fittings. When the welder gets the mechanics of the weld process correct and you get a good feeling .,then give them a fitting,
You also may want to checkout a socket weld removal tool like the Wachs linked below.
htt
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
If it is Monel, it is not hardenable like steel, but is not as machineable in general. Just google to find a machineability index for it.
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
On-line catalog page 2359 is the "About Band Saw Blades" page.
RE: Help Stop Wasting of Student Welding Materials
Mike Halloran
Pembroke Pines, FL, USA
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
_____________________________________
"The richer we have become materially, the poorer we have become morally and spiritually." Martin Luther King Jr
RE: Help Stop Wasting of Student Welding Materials
These temperatures and rates are pretty important so you get the right microstructure so you may need to do some research or consult an engineer.
or go with the easy option of using CS :/.
RE: Help Stop Wasting of Student Welding Materials
These students do start off with Carbon Steel and move on to monel latter on. I am sorry to every one for providing a poor example, but my main concern is saving material. When they reach monel the are proficent enough to be tested. I did not have a monel photo to provide.
RE: Help Stop Wasting of Student Welding Materials
What is a CS :/. ?
RE: Help Stop Wasting of Student Welding Materials
machining the fittings?
using oxy-acetylene machine?
using plasma cutting machine?
shearing the metal in an iron worker?
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
It will crush fittings and pipe before shearing them.
Oxy-acetylene and plasma will cut the pipe easily, but leave a HAZ and a mess of burnt metal around the cut.
Grit-edge bandsaw blades will go through pretty hard stuff, cleanly. You should be able to saw pipe off right next to the weld, maybe partly through the weld if you are careful about the guides. Then you can machine the sockets, e.g. in a lathe. You'll probably need a four jaw chuck, and indicate the ID of the pipe, or maybe the root of the socket, to bore out the old pipe. A good machinist could probably face off the weld and bore the pipe enough to allow collapsing the OD with a chisel without cutting the actual socket very deep.
Mike Halloran
Pembroke Pines, FL, USA
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
RE: Help Stop Wasting of Student Welding Materials
You could support the inside of the pipe with a loose-fitting round that's also sheared, but the pipe will be ovalized.
You could use a tight-fitting round, but then you have to drive the round out of the sheared pipe.
You could use a round as a mandrel, i.e. insert it just short of the shearing plane, but someday it will get sheared, and usually it won't be inserted far enough, so the pipe will be distorted.
Arun's idea, an abrasive chop saw, is probably quicker.
Mike Halloran
Pembroke Pines, FL, USA
RE: Help Stop Wasting of Student Welding Materials
You should be able to control the carbon steel socket and pipe. Make sure they both have a CE < 0.3 or so and you should be able to cut as close to the weld as the DoAll will get without hurting the blades.
RE: Help Stop Wasting of Student Welding Materials