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#1
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What was that welding exercise/exam?
Somewhere I read about a welding exercise where the student built a
tube frame of some sort, pressurized it, checked for leaks, then smashed it flat and rechecked for leaks. I've looked thru my books but can't find it. Anyone recall where I can find a description of the exercise? - Mike |
#2
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What was that welding exercise/exam?
mhorowit wrote: Somewhere I read about a welding exercise where the student built a tube frame of some sort, pressurized it, checked for leaks, then smashed it flat and rechecked for leaks. I've looked thru my books but can't find it. Anyone recall where I can find a description of the exercise? - Mike Here is an idea:- "Build a tube frame of some sort, pressurise it, check it for leaks, then smash it flat and recheck for leaks." Sorry - but you seem to have covered all of the bases^H^H^H^H^H requirements already. Oh, maybe you want to know how to interpret the results. If it leaks you failed:-) |
#3
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What was that welding exercise/exam?
On 12 Jul 2006 04:58:49 -0700, "mhorowit" wrote:
Somewhere I read about a welding exercise where the student built a tube frame of some sort, pressurized it, checked for leaks, then smashed it flat and rechecked for leaks. I've looked thru my books but can't find it. Anyone recall where I can find a description of the exercise? - Mike I have no idea what any official test looks like except a vague recollection that the australian test was an N shape coming up off a tube. you had to weld it bolted vertically up off a bench to demonstrate welding in all positions. it was then sliced up to check for carbon and impurities in the weld. there was also a set of butt welds in sheet. I have a friend who is a crackerjack welder but lacked the confidence to tackle a welded tube airframe. even after he welded a tailwheel that I flew across australia and back. I had him weld up a square in tubing using a different type of joint in each corner. he then stressed this to destruction in a press. it took two tons to destroy each corner and the joint failure was in the tubes a little way off beside the weld. with that reasurance he has almost completed an absolutely schmick low wing sonerai two. try it it worked for him. Stealth Pilot |
#4
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What was that welding exercise/exam?
"mhorowit" wrote in message oups.com... | Somewhere I read about a welding exercise where the student built a | tube frame of some sort, pressurized it, checked for leaks, then | smashed it flat and rechecked for leaks. | I've looked thru my books but can't find it. Anyone recall where I can | find a description of the exercise? - Mike | My instructor had me butt weld some tubing in a vertical as well as a horizonal position. Then grind off the weld until flush with the surface of the tubing. Then cut the tubing into strips across the weld approximately 3/8" wide. Then clamp each strip in a vise about an inch away from the weld and bend the tubing back and forth until it breaks. A break outside of the weld is a passing grade. A very humbling experience at the time. -- Jarhead ----== Posted via Newsfeeds.Com - Unlimited-Unrestricted-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 100,000 Newsgroups ---= East/West-Coast Server Farms - Total Privacy via Encryption =--- |
#5
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What was that welding exercise/exam?
"Jarhead" wrote My instructor had me butt weld some tubing in a vertical as well as a horizonal position. Then grind off the weld until flush with the surface of the tubing. Then cut the tubing into strips across the weld approximately 3/8" wide. Then clamp each strip in a vise about an inch away from the weld and bend the tubing back and forth until it breaks. A break outside of the weld is a passing grade. A very humbling experience at the time. The big thing missing with that exercise is checking for pinholes in the weld, which would cause a leak. If the joint leaks, it lets moisture into the inside of the tubes and promotes rust. Some tube framed aerobatic aircraft have a pressure tap fitted to the tube in a prominent place. The tubes are assembled with holes joining one tube to the next. After welding, linseed oil is put inside the tubing (to prevent rusting), then rotated around and drained out. The fuselage tubes are then pressurized with nitrogen. If on the preflight, the pilot sees that the gauge has dropped to zero, then he/she knows that there is a crack in the frame somewhere, and to find it and fix it. All in all, another very good way to make sure your airplane is not going to fall apart, with you in it. That would be a "bad thing." g -- Jim in NC |
#6
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What was that welding exercise/exam?
"Morgans" wrote in message ... "Jarhead" wrote My instructor had me butt weld some tubing in a vertical as well as a horizonal position. Then grind off the weld until flush with the surface of the tubing. Then cut the tubing into strips across the weld approximately 3/8" wide. Then clamp each strip in a vise about an inch away from the weld and bend the tubing back and forth until it breaks. A break outside of the weld is a passing grade. A very humbling experience at the time. The big thing missing with that exercise is checking for pinholes in the weld, which would cause a leak. If the joint leaks, it lets moisture into the inside of the tubes and promotes rust. Some tube framed aerobatic aircraft have a pressure tap fitted to the tube in a prominent place. The tubes are assembled with holes joining one tube to the next. After welding, linseed oil is put inside the tubing (to prevent rusting), then rotated around and drained out. The fuselage tubes are then pressurized with nitrogen. If on the preflight, the pilot sees that the gauge has dropped to zero, then he/she knows that there is a crack in the frame somewhere, and to find it and fix it. All in all, another very good way to make sure your airplane is not going to fall apart, with you in it. That would be a "bad thing." g -- Jim in NC Instead of filling with nitrogen, fill with argon while the frame is being welded. This keeps the inside of the weld as clean as the outside. A low flow rate is ample as it doesn't bleed to atmosphere as easily as the outside of the tubing. The same pressure gauge will provide years of confidence in the airframe integrity. Stealth, send your welding samples to ETRS Pty. Ltd, 1 Acirl Street Ipswich Qld, not sure of postcode. Their website http://www.etrs.com.au/ is being updated at the moment, due to a company buyout, talk to Mike Lynham in Ipswich about what samples are required for aircraft welding test. They will destructively test and certify the welding. Hope this helps, Peter |
#7
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What was that welding exercise/exam?
mhorowit wrote: Somewhere I read about a welding exercise where the student built a tube frame of some sort, pressurized it, checked for leaks, then smashed it flat and rechecked for leaks. I've looked thru my books but can't find it. Anyone recall where I can find a description of the exercise? - Mike Take a 6 inch pipe. Fishmouth one end with 45 degree bevels, then keep cutting all the way through the pipe along those same angles. Do it again. Weld a shrader valve into one of the pieces, then weld the whole thing (4 pieces) together. Does it hold air? Good. Now squash it flat. If it still holds air, you can weld pressure vessels for nuclear applications. I could have the details a little off on the fabrication, but that's the general scheme of it. |
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