I have to say that, if this one video is any indicator to me, you are a great machinist and an excellent teacher! You laid out all of the information in a logical way, took me step by step through the process, and showed me the end result. I have subscribed so that I can learn more.
Very good video! Back in the 1990s I had a 3" or 4" by about four foot long shaft repaired by spray weld, as far as I know it is still running 40 years later. It was a large blower fan (60 HP or larger) on an air handler, first we had some vibration, than it became a rumble and then we found the culprit. The worn shaft was spinning in the bearing. A new shaft would have been a lot more cost than the repair was and we also replaced the bearings.
Outstanding work have not seen this in the UK since the 70s , people have signed up for the throw away society now, decreasing number of skilled people like this. Thank you for video.
Great camera angles on the spray welding. The multiple angles really make for a professional looking video. A lot of people think making videos is easy. The editing for this multiple angles is a lot of work
I never even knew about spray welding till I came to your channel. It is such a hush hush process that my welding supply co doesn’t even know about this, or they are just playing dumb, but I really don’t see why they would do that and loose a sale for this stuff, because it is diffinately not cheap, but it is a hell of allot cheaper than making a new part or other repairs like sleeving. Thank you for making these types of videos, very enjoyable and I have learned allot from watching you. P.S. It was great to see your wife involved in the video making, it looks like she really enjoys being there with you. Hope you two have a great Easter weekend. Jeff from Michigan
Its an amazing blast from the past I have never done spray welding myself however I started out in as a machinist in a die press manufacturing company in the machine shop, The welding department would do tons of spray weld repairs on crown belt pulley shafts and even on former tool shafts that ran directly on oiled bronze bushing. The pulley shafts were long and drove lines of presses with bearings spaced down the line it was a cost effective solution to scraping the shaft. The repairs were done often and don't remember any failures. Very cool to see it done by a pro Thanks for sharing
Just the level of ease they have it’s like they’re tying their shoes, no effort and you can tell they’re not even thinking about it, just comes naturally
We took the camera off to edit first LOL nobody is that good there are problems that do arise that aren't the norm so even if you are the baddest of the baddest and the best of the best there is someone that will throw a wrench into your plan and you have to work behind them and figure out what they did and why so that it doesn't happen again he can implement similar logic if it applies meaning the job will be a normal job minus the time consuming Mickey mouse but still I understand there are only certain parts in certain places at certain times and if you haven't found your niche place or if you are out of your area you get innovative LOL
Sir thank you very much for sharing such a great video I am not engineer nor anything to do with engineering or metal worker but totally enjoyed your video you are a true craftsman I really respect what you do. Videos like this will shed a light in the future on how things were done, I tell you something I'll watch your other videos too really interesting. Respect
It may well have been manufactured in Germany. I know a lot if heavy, precision machinery is. Not all, I could be wrong, just an educated guess based on past experience.
Back in the late 1970's the Aussie army was using this method to repair worm drive sprockets on M113 APCs and the finished repair was harder and wore better than the brand new replacement parts. If i remember the repaired parts would last 3 times the brand new ones this was because they were able to put a harder build up on the wear area of the sprocket to the cast hardness
@@paulhickey4485 same process basically. But uses a wet oil fed quenching clamp with hardening oil on it . Spray weld , then immediately apply the clamp on just the area that needs hardened on the shafts or race areas. Saw this done at rayethon before on sealed drive motor systems in the 90s that were used in areas that were very inaccessible, high heat or that needed extreme long life intervals, (years) between servicing. New build process. Not repair like this as far as I know. But may have been used for rebuilding.
I don't know how about You but I really enjoy that kind of work just because there are few people that know how to do it. I serviced concrete mixing plants for a while and it's not about money but it's cool to know that only few dozen people in the world know how to do this.
Couple of things First Wonka wants his giggles back Next, most impressive, three cameras on the spray welding, amazing!! Lastly ... Abom79, a family production!!
Hi, really enjoy watching your videos here in Scotland! Hope you don't mind me making a couple of comments - I worked for Castolin Eutectic for 30+ years and trained oxy fuel thermal spray system users. First observation relates to use of screw threading for preparation - I have never used this as a prep method for a couple of reasons. The potential benefit of screw threading is to increase the effective surface area available for the coating, but there are some factors that can limit this effectiveness. 1. unless the threading is done correctly (ie. rounded tip and root profiles) there is a risk of heat oxidising the tips of the threads which will reduce or prevent effective adhesion of the bond coat. 2. If the thread pitch is too narrow in the root there may be voids, again reducing the effective area available for adhesion. 3. Threading preparation normally omits what for me is another vital step (which may answer questions raised by some of your other viewers regarding causes of coatings shelling) - oxidation forming during the preheat stage. One of the key reasons for coating failure at the initial stage in my experience is applying bond coat on top of a surface that became oxidised during preheat. This is normally indicated by surface discolouration, usually evidenced immediately on applying heat. This is diffucult to see on a screw threaded surface, but becomes very visible if alternative preparation methods are used. So, I normally advise preheating, then final preparation. This is easier to do if it is possible to a, grit blast or b. random grind with a small grinder (with a clean disk). Step b. is usually easier since the initial set up of the part doesn't need to be disturbed. The clean, random ground surface is ideal for applying the bond coat to - but preheat, final light grind back to clean metal and immediately apply the bond coat. It would be worth trying this method, what you should see on applying heat is the formation of a brown discolouration on the surface - coating on top of this (as is likely happening) is most likely compromising the coating bond effectiveness. Just give a final light grind back to bright metal and proceed from there. Hope this helps!
If I recall correctly,we were told. To use a 90 degree too tip to cut the thread so that the root and crest of the threads were broad, and were therefore more resistant to overheating.
What do I know about spray welding? A tiny amount. What do I know about using a lathe? A tiny amount. Do I enjoy watching a craftsman do his work? A huge amount. Thanks for sharing your knowledge and skills, you have a easy style that makes it interesting and informative. Proper 😀
As an apprentice millwright, I find that many tradesman go the extra mile to do a good job. Settling for nothing but the best way. Theres always a few hacks. Just take pride and ownership in your job and it will pay off every time, regardless of the industry you're employed in.
@Igor Stephonivich Crash not in a capitalist world. it's nice that capitalism is losing supporters as generations come and go. soon we will have all working people taking pride in their jobs. Sadly, the way it is now, people's pride and values can be easily bought off in a world where money is everything.
@@Ryzot - Capitalism is freedom to do your best, the better your product the more the reward. Some people like the state to take care of them and other people like to take care of themselves. You can not group all people as one kind, if you want to live in China, Cuba, North Korea, Venezuela, Finland, Germany, etc. go ahead but I'm staying right here, and loving it!
Thanks for demonstrating this very interesting process and kudos to your skills and knowledge, the praise is well deserved - but I must ask, please, please please, don't polish rotating shafts by holding abrasive paper loops against it with your fingers. I work in Australia as a safety professional. I have attended an incident where a machinist with 30 yrs experience, very careful, regarded as all his colleagues as being one of the safest operators they know was doing this and it grabbed - his arm was pulled in and twisted around the shaft resulting in multiple breaks and many, many months of recovery. He said he was holding by just the fingertips, believing it would just pull free from his fingers; it doesn't. Before you can react it can pull your arm into the lathe. He is unable to return to work and was lucky not to have had his arm amputated. I know of two others who did lose their arms, torn off by the incident. One of them unfortunately died from his injuries. I know many machinists use this method and luckily do so for many years without injury - but it only has to go wrong once........... and I've also seen over many years and many incidents, the lasting impact such an event has on family and colleagues of injured workers. I suggest one method you could use is a frame to hold the abrasive, you can still control the pressure applied and if it catches, the paper just comes loose - you're left holding the frame, with no injury. I'm not saying this to put a downer on your work, quite the opposite - I just want to be able to continue to enjoy watching you do your thing well into the future. You (rightly) should be proud of the care and expertise you clearly put into your work; because your channel is popular, I hope it would also be an opportunity to educate others in the safest techniques possible.
Hi, enjoyed the video. In the Aerospace industry they refurbish parts using plasma spraying, and Ford uses the same process to refurbish cracked engine blocks. My only concern is that you made no mention if the part had been X-rayed to check for cracks. I say this because if the parts does fail and it had cracks and it ended up fouling the whole assembly your fixed part goes into, then the easiest way to put the blame on you is to claim your work failed when in fact it was the operator who failed to make proper adjustments and caused the damage. I speak from personal experience having worked in the oil and gas inspection services sector, and my son is a parts tester for a major oil and gas service provider. In one incident a part my son's company made was accused of failing causing over a billion dollars in damages. Since my son is the top tech , he was tapped to simulate the proper installation of the part compared to the video and notes by the oil platform tech who installed it and had it failed. An international group arrived which consisted of the owners of my son's company and owners of the oil company and their top engineers. Well my son demonstrated perfectly how the part was to be properly installed, and he was able to show the part could be taken above stated maximum tolerances and still not fail. Then he replicated what the oil company did installing the part and he showed how it started to fail when a load started being put on it. The oil company's own engineers conceeded that the part had been improperly installed and the multi billion dollar contract resume and the lawsuit dropped. To protect yourself from being shaken down by a company who is trying to shift the blame for their own mistakes and armature repairs, demand the part be properly inspected and x-rayed before doing any work. And make sure you get to see the x-ray and notate on your work orderform any areas of concern before attempting any repairs. And make sure to properly notify the owners of the part in writing what you found before you start. The saying goes... the last person who fixed it is to blame. So please be careful, from my viewpoint it looked like there was some evidence of stress fractures on the upper part of the shaft that was all beat up. Carpe Metallum!
I am just an old mechanic, retired a few years back from my now 92. Many time during my career, I had wished to have grown from childhood as some I have known, who learned as apprentice in their professional parent's machine shop. I highly admire the skill diplayed here, and compliment much this consciensious professional. Bless him in his work, and may he be ever successful and admired and emulated. Just plain Fritz
I'm a retired jewellery polisher and love to watch skilled folks working through problems. I always feel one step closer to God when viewing the very best that humanity has to offer.
Hi, I am a retired Eutectic Sales Manager. I thoroughly enjoyed your video and it brought back a lot of memories, especially the one's where I trained engineers in Africa on the benefit's of investing in this technology. We live in a throw away world, and when we see a worn part it's easy to go and buy a new one. Invariably, the part that's worn only represents 5% of the total part, so we are actually throwing away our own money! It really is a simple piece of kit to use, and like you say, just follow the instructions. Glad to see someone still using the Rototec system.
As of today 803 thumbs down. I am amazed at how many people that are so gifted that they can be so critical of his effort to give useful information and entertainment. I just wish there was more accountability in these comments. KEEP UP THE GREAT WORK
Hey, no worries…thanks to Bye,Done! and his amazing popularity (/s); YT is no longer letting anyone know (publicly, at least) how many thumbs down a video has received! In other words, we deal with tanking political public approval by CENSORING!!! YAY! Cheers, and who cares about the haters? They’re not who you make the videos for anyway!
You do great work both on the lathe, welding and with the camera - some real talent going on there - I'm really glad that I took the time to watch the entire episode and there's not may videos that you can say that about Maginifcent
I was hired on to a factory back in the early 1990's. They gave me the job because I was the only applicant who could spray weld. I ended up spending six years sitting on a chair spraying finger sized casting to harden them. When I took the job I was given a coffee can full of the clips to demonstrate my ability. I didn't know there was a warehouse full of 55 gallons drums of the exact same clips to be sprayed.
This is what YT is about for me. Not some silly ass influencers and their bullshit. I prefer watching content like that, with hardworking, skilled people at work!
Wow, your camera girl is pretty good. Good framing. But the icing on the cake is those goggles. I expected to see Mad Max come charging in to get his goggles back! Seriously though. Some people like windchimes to soothe their weary mind... But I could watch this metalworking all day... It's just relaxing to watch a skilled tradesman work out a masterpiece.
I'm not a welder of any sort. I have no aspirations to be a welder or machinist. But I've just watched this entire video to see a master craftsman at work.
True! I'm and IT guy and I love this!! :DD (but until I was 12 I helped my uncle every day with machining & repairing agricultural machines and cars/trucks)... Kinda reminds me on my young days ...
Thank you for sharing with us. This is the kind of repairs Dad, Jack Karp, used to do for Commercial Fisherman in South Beach, OR. I hadn't seen this tool in many years. Reminded me of the 1980's, watching Dad do repairs for a good price, high quality & timely delivered to get them back to sea fishing. He could fix it better, quicker & cheaper. He liked his work to be perfect. I miss him.
Quality of craftsmanship at its finest.. I'm a machinist myself by trade and this is a lost art rarely seen or done due to Advanced Machinery that can spit out parts at a mass rate .but Robotic machines like that dont put blood sweat and tears into there work. thank you for sharing your knowledge and inspiration for the industry . thank you for sharing your talent with all of us out there ..vary much appreciated respect that's all I have to say
Hey Adam.. just wanted to leave ya a note to let you know that we think that you are amazing and awesome. And to thank you for all that you do, for us and for everyone. You really are very intelligent and it's cool that you share that wisdom and knowledge with the rest of us. It's very much appreciated. And even more awesome is that you share wisdom and knowledge that is beneficial and helpful to myself and others!! 🤗🤗🙂🙂🙃🙃😀😀😃😃😁😁. I hope that all is well for you and your family and for Abby too!! 👍👍..have a blessed day and week. Thank you again for all that you do Adam and Abby!! Asalaam ✌️ Peace
I don't know who's hating on you for spray welding rather than sleeving, but I trust you more than I trust some anonymous jackass. I'm sure there are instances where one is better than the other, and I'm sure you'd tell us if that were the case.
That spray welding is a process that if you hadn't known about it, and someone told you it would work, 99.9 % of people would say you're crazy, and laugh. Amazing how that flame keeps oxygen in the air from burning up the metal powder before it reaches the work piece. And how those particles can bind to the relatively cool metal shaft. It shows how the bond is at the atomic level, right at the surface. Like when steel cutting torch slag sticks to concrete. I've got some on my driveway that a pressure washer didn't dislodge. The camera work was outstanding.
What a pleasure to see a professional tradesman at work. Good onya mate. Such a thorough and beautiful job. Fantastic dialogue too, really well explained. I remember seeing the machinists do this when I was an apprentice mechanic in the 1970's. It was Eutectic Castolin equipment too. They sprayed crankshaft journals where the bearings had spun. Quite amazing. How tough is that shielding paint!
Folks might be asking... and why not use regular welding rods and rebuild the worn out shaft? This is the first mistake mechanics do in their life.... weld a shaft! A shaft cannot be welded ever, all the steel mechanical properties are lost if a welding rod is applied. This process is known as a low temperature metallizing. Temperature is kept below annealing so steel properties are not changed.
More than likely a Mild Steel shaft, thus with a low carbon content of approximately 0.05-0.30% carbon if same no heat treatment process apart from Case Hardening, could be carried out on same, the Kicker is whatever about the cost ... quick turnaround as this item the priority Time is Money ... or may have been taken out during, an annual Plant "Shutdown" so was wanted back ASAP for Millwrights to rebuild same... saves having same being as it could be a high cost Stores Item just sitting for a decade on a Shelf, He's correct, once heat would go into that Journal the effect would allow the shaft to kick off and deflect for a pastime, with little prospect of getting the same back to run true.
Carlos, I worked for an engine rebuilder for 14 years and he would weld crankshafts that were complete JUNK! He welded 2 marine engines on a raceboat that were doomed to failure. The boat didn't make it out of the harbor when BOTH crankshafts failed!
Really nice job, it's good to see real tradesperson doing a proper job. I work in maintenance shop and it is very hard to find a good machinist. Keep up the good work!
I used to work for Qantas Engineering and it was common to do plasma spray repairs on 747 engine parts. We even had a plasma spray robot that would take parts up to 8 feet in diameter. Sadly all that world class engineering facility has now been shut down and all that expertise has been lost.
There lays the issue... If you really want to America Great Again then bring it Home... We have to atary teaching the youngster how to do things again before it is too late... Yhe past 6 weeks should teach them something about when something hugh takes place and you have to rely on other countries to make basic things like gloves and mask for you... what if they refused.
Isn't that the truth our government shut down the worlds best steel products. I lived in Ohio and all huge steel mills along the Ohio river shut down. Pennsylvania Michigan all ghost mills
Love seeing old techniques still being used in modern times. Time is money to everyone and spray welding done right will save a lot of time and bring in a lot of customers. Well done!
FYI, if your fingernail catches on something, that something is .003" thick or more. Under .003, your fingernail won't catch. That's a masters level biotech engineering "rule of thumb".
Randomly stumbled on this video. I have zero engineering / technical skills and still had fun. I'm not sure if I enjoyed the technical demonstration or your camera presence and dialogue more. Keep it up.
I am beyond impressed by your level of expertise and craftsmanship. Utterly fascinating seeing this hidden world. You are truly an awesome example as to why we should encourage young people to consider trade schools and the like.
In the 1950s I was a 17 year old machinist mate in the after engineroom of the USS Kearsarge, CVA33, an Essex class aircraft carrier. Because I was rated (schooled), I was allowed access to the ship’s machine shop where I developed skills with a lathe and even a shaper. All the guys in this compartment were old salts and mostly interested in lounging and drinking coffee, but I loved making things here when I was not on duty in the engineroom. I began getting jobs making aircraft parts and things for the two galleys. Loved it all. I used many of these skills later when I became a jeweler. You seem like me in the sense you obviously love and enjoy your work. I was NEVER close to being as good as you, though. Thanks for the channel.
This is the stuff about machining I always enjoyed, fixing random stuff. Maybe someday when I'm too stoved up to keep logging I'll get me a mill and lathe and spend my retirement tinkering with stuff. 25 years machining, did it all, but they don't want experience anymore they wan't grunt labor, so back to the woods I go
You are a great presenter! That's a great skill beyond the machining. One of the best RUclips videos I've seen on any subject. Good job. I worked in factories where we occasionally had shafts spray welded but I never saw the whole process up close.
I'm glad almost 2 years later this video is getting a lot of attention. These processes are VERY interesting and amazing to see. thanks for filming this!
I loved watching this! Learnt a ton, but now I have an urge to acquire a rototec... 🤣
It's quite the spectacle, seems right up your alley! Plus I'm sure you wouldn't mind fixing slightly undersized parts
Have you tried anything like this yet Alec?
I agree I loved watching this too.
@@Handsy_McGee Q¹²¹²²5
Lol you watch this i always watch your channel lol 🤣
Bro those welding goggles make you look like Maz Kanata from Star Wars...😝😄😆
I have to say that, if this one video is any indicator to me, you are a great machinist and an excellent teacher! You laid out all of the information in a logical way, took me step by step through the process, and showed me the end result. I have subscribed so that I can learn more.
Very good video! Back in the 1990s I had a 3" or 4" by about four foot long shaft repaired by spray weld, as far as I know it is still running 40 years later. It was a large blower fan (60 HP or larger) on an air handler, first we had some vibration, than it became a rumble and then we found the culprit. The worn shaft was spinning in the bearing.
A new shaft would have been a lot more cost than the repair was and we also replaced the bearings.
Outstanding work have not seen this in the UK since the 70s , people have signed up for the throw away society now, decreasing number of skilled people like this. Thank you for video.
Am I a welder? No.
Am I a machinist? No.
Am I under the quarantine spell, watching random awesome videos for hours on end? Yes.
Great camera angles on the spray welding. The multiple angles really make for a professional looking video. A lot of people think making videos is easy. The editing for this multiple angles is a lot of work
I never even knew about spray welding till I came to your channel. It is such a hush hush process that my welding supply co doesn’t even know about this, or they are just playing dumb, but I really don’t see why they would do that and loose a sale for this stuff, because it is diffinately not cheap, but it is a hell of allot cheaper than making a new part or other repairs like sleeving. Thank you for making these types of videos, very enjoyable and I have learned allot from watching you. P.S. It was great to see your wife involved in the video making, it looks like she really enjoys being there with you. Hope you two have a great Easter weekend.
Jeff from Michigan
Its an amazing blast from the past I have never done spray welding myself however I started out in as a machinist in a die press manufacturing company in the machine shop, The welding department would do tons of spray weld repairs on crown belt pulley shafts and even on former tool shafts that ran directly on oiled bronze bushing. The pulley shafts were long and drove lines of presses with bearings spaced down the line it was a cost effective solution to scraping the shaft. The repairs were done often and don't remember any failures. Very cool to see it done by a pro Thanks for sharing
The spray welding is really cool, but we all have to be honest about it; it's mainly because of THOSE GOGGLES!!!!!!
Biggles
I’ve come to a conclusion; watching people at the top of their game doing what they do is somewhat soothing
Just the level of ease they have it’s like they’re tying their shoes, no effort and you can tell they’re not even thinking about it, just comes naturally
We took the camera off to edit first LOL nobody is that good there are problems that do arise that aren't the norm so even if you are the baddest of the baddest and the best of the best there is someone that will throw a wrench into your plan and you have to work behind them and figure out what they did and why so that it doesn't happen again he can implement similar logic if it applies meaning the job will be a normal job minus the time consuming Mickey mouse but still I understand there are only certain parts in certain places at certain times and if you haven't found your niche place or if you are out of your area you get innovative LOL
Ain't it
?
I agree. I just feel so much more relaxed after now that I watched this. glad I'm not the only one understand this!
I randomly stumbled across this, but watched the whole thing and enjoyed it. Truly fascinating.
Came here to say the same thing!
Same here
+1
Exactly!! Wow. Amazing.
Me as well
Sir thank you very much for sharing such a great video I am not engineer nor anything to do with engineering or metal worker but totally enjoyed your video you are a true craftsman I really respect what you do. Videos like this will shed a light in the future on how things were done, I tell you something I'll watch your other videos too really interesting. Respect
Glad to see Abby out in the shop. I'm retired from a naval shipyard and the flame spray process was used extensively to repair high end components.
3.9369 in = 100 mm +/- 0.003
mm
Whatever it is, it was designed in metric
god the imperial system is trash the US needs to switch to metric
It may well have been manufactured in Germany.
I know a lot if heavy, precision machinery is. Not all, I could be wrong, just an educated guess based on past experience.
Adam you are one hell of craftsman i truly enjoy to watch and learn from, Keep the good work up, and keep them coming 👍👍👍
Fine work with good detailed instructions from start to finish. The future of education and learning.
For anyone wondering about the oddball size...3.9369*25.4 = 99.99726 so 100mm bearing
I didn’t ask.
@@GardenGuy1942yeah, no one asked for your comment either bud...
Back in the late 1970's the Aussie army was using this method to repair worm drive sprockets on M113 APCs and the finished repair was harder and wore better than the brand new replacement parts. If i remember the repaired parts would last 3 times the brand new ones this was because they were able to put a harder build up on the wear area of the sprocket to the cast hardness
Also the spray material has micro pockets that hold oil better
I doubt it was the cold process as shown here. The application you describe may have been a fusion process which looks similar to this.
@@paulhickey4485 same process basically. But uses a wet oil fed quenching clamp with hardening oil on it . Spray weld , then immediately apply the clamp on just the area that needs hardened on the shafts or race areas. Saw this done at rayethon before on sealed drive motor systems in the 90s that were used in areas that were very inaccessible, high heat or that needed extreme long life intervals, (years) between servicing. New build process. Not repair like this as far as I know. But may have been used for rebuilding.
my boi lookin like doctor octavius with those goggles lol great work 👍
Watching your professional approach and degree of care restores my faith humanity. I'm glad that there's still people like you around.
Only heard about this technique, now I've seen it. Outstanding job, thank you so much for sharing!
Great old-school machining. Like so many other things, it's a dying art. Well done sir.
Fantastic video again, as were the other 299. Congrats on 300th. Keep up the good and well appreciated work. Stay safe. P.
I don't know how about You but I really enjoy that kind of work just because there are few people that know how to do it. I serviced concrete mixing plants for a while and it's not about money but it's cool to know that only few dozen people in the world know how to do this.
Couple of things
First Wonka wants his giggles back
Next, most impressive, three cameras on the spray welding, amazing!!
Lastly ... Abom79, a family production!!
since I was a quality inspector in the past. It is refreshing to see a machinist/ craftsman that has good attention to detail. Subscribed.
Hi, really enjoy watching your videos here in Scotland! Hope you don't mind me making a couple of comments - I worked for Castolin Eutectic for 30+ years and trained oxy fuel thermal spray system users. First observation relates to use of screw threading for preparation - I have never used this as a prep method for a couple of reasons.
The potential benefit of screw threading is to increase the effective surface area available for the coating, but there are some factors that can limit this effectiveness.
1. unless the threading is done correctly (ie. rounded tip and root profiles) there is a risk of heat oxidising the tips of the threads which will reduce or prevent effective adhesion of the bond coat.
2. If the thread pitch is too narrow in the root there may be voids, again reducing the effective area available for adhesion.
3. Threading preparation normally omits what for me is another vital step (which may answer questions raised by some of your other viewers regarding causes of coatings shelling) - oxidation forming during the preheat stage.
One of the key reasons for coating failure at the initial stage in my experience is applying bond coat on top of a surface that became oxidised during preheat. This is normally indicated by surface discolouration, usually evidenced immediately on applying heat. This is diffucult to see on a screw threaded surface, but becomes very visible if alternative preparation methods are used. So, I normally advise preheating, then final preparation. This is easier to do if it is possible to a, grit blast or b. random grind with a small grinder (with a clean disk). Step b. is usually easier since the initial set up of the part doesn't need to be disturbed. The clean, random ground surface is ideal for applying the bond coat to - but preheat, final light grind back to clean metal and immediately apply the bond coat.
It would be worth trying this method, what you should see on applying heat is the formation of a brown discolouration on the surface - coating on top of this (as is likely happening) is most likely compromising the coating bond effectiveness. Just give a final light grind back to bright metal and proceed from there. Hope this helps!
If I recall correctly,we were told. To use a 90 degree too tip to cut the thread so that the root and crest of the threads were broad, and were therefore more resistant to overheating.
Great to see proper old school engineering by a talented old school engineer :-)
me " wth is spray welding?"
me after 20 mins " I LOVE SPRAY WELDING"
Every time you grind something on a pedestal grinder you're doing a micro version of spray welding.
I’ve never heard of it but I like it
What do I know about spray welding? A tiny amount. What do I know about using a lathe? A tiny amount. Do I enjoy watching a craftsman do his work? A huge amount.
Thanks for sharing your knowledge and skills, you have a easy style that makes it interesting and informative. Proper 😀
There’s a man who takes incredible pride in his work.
...a man **who can** take incredible pride in his work.
Litch anyone can take pride in their work. You just have to want to do it.
As an apprentice millwright, I find that many tradesman go the extra mile to do a good job. Settling for nothing but the best way.
Theres always a few hacks.
Just take pride and ownership in your job and it will pay off every time, regardless of the industry you're employed in.
@Igor Stephonivich Crash not in a capitalist world. it's nice that capitalism is losing supporters as generations come and go. soon we will have all working people taking pride in their jobs. Sadly, the way it is now, people's pride and values can be easily bought off in a world where money is everything.
@@Ryzot -
Capitalism is freedom to do your best, the better your product the more the reward. Some people like the state to take care of them and other people like to take care of themselves. You can not group all people as one kind, if you want to live in China, Cuba, North Korea, Venezuela, Finland, Germany, etc. go ahead but I'm staying right here, and loving it!
It's like watching someone like Da Vinci painting. Thank you for taking the time to make this.
I love the goggles you’re wearing while spray welding! What are they?
Thanks for your time very interesting stay safe Danny Woodliff
I’m the kinda of guy that left witness marks with a pipe wrench
I’m the guy who cut 50 pieces 1/2 inch short and said “close enough”
@@guybuddyman838 😊
Thanks for demonstrating this very interesting process and kudos to your skills and knowledge, the praise is well deserved - but I must ask, please, please please, don't polish rotating shafts by holding abrasive paper loops against it with your fingers. I work in Australia as a safety professional. I have attended an incident where a machinist with 30 yrs experience, very careful, regarded as all his colleagues as being one of the safest operators they know was doing this and it grabbed - his arm was pulled in and twisted around the shaft resulting in multiple breaks and many, many months of recovery. He said he was holding by just the fingertips, believing it would just pull free from his fingers; it doesn't. Before you can react it can pull your arm into the lathe. He is unable to return to work and was lucky not to have had his arm amputated. I know of two others who did lose their arms, torn off by the incident. One of them unfortunately died from his injuries. I know many machinists use this method and luckily do so for many years without injury - but it only has to go wrong once........... and I've also seen over many years and many incidents, the lasting impact such an event has on family and colleagues of injured workers. I suggest one method you could use is a frame to hold the abrasive, you can still control the pressure applied and if it catches, the paper just comes loose - you're left holding the frame, with no injury. I'm not saying this to put a downer on your work, quite the opposite - I just want to be able to continue to enjoy watching you do your thing well into the future. You (rightly) should be proud of the care and expertise you clearly put into your work; because your channel is popular, I hope it would also be an opportunity to educate others in the safest techniques possible.
Thanks for this.
Thanks for this.
I am glade to see that you took the time you explain your self and you did a nice job in doing so on your safety concerns 😟👍
Hi, enjoyed the video. In the Aerospace industry they refurbish parts using plasma spraying, and Ford uses the same process to refurbish cracked engine blocks. My only concern is that you made no mention if the part had been X-rayed to check for cracks. I say this because if the parts does fail and it had cracks and it ended up fouling the whole assembly your fixed part goes into, then the easiest way to put the blame on you is to claim your work failed when in fact it was the operator who failed to make proper adjustments and caused the damage. I speak from personal experience having worked in the oil and gas inspection services sector, and my son is a parts tester for a major oil and gas service provider. In one incident a part my son's company made was accused of failing causing over a billion dollars in damages. Since my son is the top tech , he was tapped to simulate the proper installation of the part compared to the video and notes by the oil platform tech who installed it and had it failed. An international group arrived which consisted of the owners of my son's company and owners of the oil company and their top engineers. Well my son demonstrated perfectly how the part was to be properly installed, and he was able to show the part could be taken above stated maximum tolerances and still not fail. Then he replicated what the oil company did installing the part and he showed how it started to fail when a load started being put on it. The oil company's own engineers conceeded that the part had been improperly installed and the multi billion dollar contract resume and the lawsuit dropped. To protect yourself from being shaken down by a company who is trying to shift the blame for their own mistakes and armature repairs, demand the part be properly inspected and x-rayed before doing any work. And make sure you get to see the x-ray and notate on your work orderform any areas of concern before attempting any repairs. And make sure to properly notify the owners of the part in writing what you found before you start. The saying goes... the last person who fixed it is to blame. So please be careful, from my viewpoint it looked like there was some evidence of stress fractures on the upper part of the shaft that was all beat up.
Carpe Metallum!
This guy is good. I would hire him any day. He does work as if it was his own.
I am just an old mechanic, retired a few years back from my now 92. Many time during my career,
I had wished to have grown from childhood as some I have known, who learned as apprentice in
their professional parent's machine shop. I highly admire the skill diplayed here, and compliment
much this consciensious professional. Bless him in his work, and may he be ever successful and
admired and emulated. Just plain Fritz
I'm a retired jewellery polisher and love to watch skilled folks working through problems. I always feel one step closer to God when viewing the very best that humanity has to offer.
Hi, I am a retired Eutectic Sales Manager. I thoroughly enjoyed your video and it brought back a lot of memories, especially the one's where I trained engineers in Africa on the benefit's of investing in this technology. We live in a throw away world, and when we see a worn part it's easy to go and buy a new one. Invariably, the part that's worn only represents 5% of the total part, so we are actually throwing away our own money! It really is a simple piece of kit to use, and like you say, just follow the instructions. Glad to see someone still using the Rototec system.
this is the first time in my life i know about Spray Welding 😅😅😅😅😅😅😅 it is amazing
As of today 803 thumbs down. I am amazed at how many people that are so gifted that they can be so critical of his effort to give useful information and entertainment. I just wish there was more accountability in these comments. KEEP UP THE GREAT WORK
totally agree - I'm often amazed how many dissenters there are.
Nice job
Hey, no worries…thanks to Bye,Done! and his amazing popularity (/s); YT is no longer letting anyone know (publicly, at least) how many thumbs down a video has received! In other words, we deal with tanking political public approval by CENSORING!!! YAY! Cheers, and who cares about the haters? They’re not who you make the videos for anyway!
In case you're wondering 3,937 inch = 100 mm
Great to see this being done again, I used to teach spray welding back in the 1980s with kit much the same as yours.
You do great work both on the lathe, welding and with the camera - some real talent going on there - I'm really glad that I took the time to watch the entire episode and there's not may videos that you can say that about
Maginifcent
As a dentist, I thought our profession did some precision work but this is just amazing! Love watching a craftsman. All the best from Scotland.
I bet your patients absolutely hate you when you start spinning them on the lathe!
When you stumble across this and really have no reason to check it out, but watching the precision work keeps you interested. Truly nice work!
27:40 The lady was looking for a compliment and you missed it. You were supposed to say, "This thermometer doesn't read that high."
I was hired on to a factory back in the early 1990's. They gave me the job because I was the only applicant who could spray weld. I ended up spending six years sitting on a chair spraying finger sized casting to harden them.
When I took the job I was given a coffee can full of the clips to demonstrate my ability. I didn't know there was a warehouse full of 55 gallons drums of the exact same clips to be sprayed.
what the hell is clips ?? just asking
I don't completely understand what I just watched, but I'm glad I found this channel.
Lol! I’m with you!
He putting metal back on that metal piece man
This is what YT is about for me. Not some silly ass influencers and their bullshit. I prefer watching content like that, with hardworking, skilled people at work!
3.9369 inches? Sure sounded like 100 mm to me. Always glad to see you using full PPE especially when you grabbed the earplugs when using the grinder.
I've sent stuff away for spray welding for years, never seen it done. Very interesting
Very steam punk look going there, especially with those goggles.
Speaking from a customers standpoint - Your attention to detail makes all the difference.
Wow, your camera girl is pretty good. Good framing. But the icing on the cake is those goggles. I expected to see Mad Max come charging in to get his goggles back!
Seriously though. Some people like windchimes to soothe their weary mind... But I could watch this metalworking all day... It's just relaxing to watch a skilled tradesman work out a masterpiece.
Not gonna lie watching metal be sprayed on is still an amazing thing to watch.
Why did RUclips recomend this? And why did I watch every second of the 51 minutes and 5 seconds of this until the screen went dark?
Adam, your attention to detail is what makes your videos worth watching. Congrats on 300 and you and Abby stay safe.
I'm not a welder of any sort. I have no aspirations to be a welder or machinist. But I've just watched this entire video to see a master craftsman at work.
True! I'm and IT guy and I love this!! :DD (but until I was 12 I helped my uncle every day with machining & repairing agricultural machines and cars/trucks)... Kinda reminds me on my young days ...
If you'd like to hear a lot of really broad spectrum music mister click on my icon it's good stuff
I used a spray welder to repair cast iron crankshaft posts that needed to repair.
Thank you for sharing with us. This is the kind of repairs Dad, Jack Karp, used to do for Commercial Fisherman in South Beach, OR. I hadn't seen this tool in many years. Reminded me of the 1980's, watching Dad do repairs for a good price, high quality & timely delivered to get them back to sea fishing. He could fix it better, quicker & cheaper. He liked his work to be perfect. I miss him.
Quality of craftsmanship at its finest.. I'm a machinist myself by trade and this is a lost art rarely seen or done due to Advanced Machinery that can spit out parts at a mass rate .but Robotic machines like that dont put blood sweat and tears into there work. thank you for sharing your knowledge and inspiration for the industry . thank you for sharing your talent with all of us out there ..vary much appreciated respect that's all I have to say
The 3.9369" = 99,997 millimeter
Means that the journal he repaired goes into something that's exactly 100mm.
@@joeylawn36111 And also that the tread is KM20 (M100x2)
Hey Adam.. just wanted to leave ya a note to let you know that we think that you are amazing and awesome. And to thank you for all that you do, for us and for everyone. You really are very intelligent and it's cool that you share that wisdom and knowledge with the rest of us. It's very much appreciated. And even more awesome is that you share wisdom and knowledge that is beneficial and helpful to myself and others!! 🤗🤗🙂🙂🙃🙃😀😀😃😃😁😁. I hope that all is well for you and your family and for Abby too!! 👍👍..have a blessed day and week.
Thank you again for all that you do Adam and Abby!!
Asalaam ✌️ Peace
I don't know who's hating on you for spray welding rather than sleeving, but I trust you more than I trust some anonymous jackass. I'm sure there are instances where one is better than the other, and I'm sure you'd tell us if that were the case.
There are some companies that will not allow you to weld on a shaft. Some make you replace them or do something like a sleeve.
That spray welding is a process that if you hadn't known about it, and someone told you it would work, 99.9 % of people would say you're crazy, and laugh. Amazing how that flame keeps oxygen in the air from burning up the metal powder before it reaches the work piece. And how those particles can bind to the relatively cool metal shaft. It shows how the bond is at the atomic level, right at the surface. Like when steel cutting torch slag sticks to concrete. I've got some on my driveway that a pressure washer didn't dislodge.
The camera work was outstanding.
RUclips: I think you would like to watch someone spray weld today. Damn if they weren't right, even if I had no idea what spray welding was.
H & H machine in St. Louis, Missouri use to do spray welding
What a pleasure to see a professional tradesman at work. Good onya mate. Such a thorough and beautiful job. Fantastic dialogue too, really well explained. I remember seeing the machinists do this when I was an apprentice mechanic in the 1970's. It was Eutectic Castolin equipment too. They sprayed crankshaft journals where the bearings had spun. Quite amazing. How tough is that shielding paint!
Folks might be asking... and why not use regular welding rods and rebuild the worn out shaft? This is the first mistake mechanics do in their life.... weld a shaft! A shaft cannot be welded ever, all the steel mechanical properties are lost if a welding rod is applied. This process is known as a low temperature metallizing. Temperature is kept below annealing so steel properties are not changed.
More than likely a Mild Steel shaft, thus with a low carbon content of approximately 0.05-0.30% carbon if same no heat treatment process apart from Case Hardening, could be carried out on same, the Kicker is whatever about the cost ... quick turnaround as this item the priority Time is Money ... or may have been taken out during, an annual Plant "Shutdown" so was wanted back ASAP for Millwrights to rebuild same... saves having same being as it could be a high cost Stores Item just sitting for a decade on a Shelf, He's correct, once heat would go into that Journal the effect would allow the shaft to kick off and deflect for a pastime, with little prospect of getting the same back to run true.
Carlos, I worked for an engine rebuilder for 14 years and he would weld crankshafts that were complete JUNK! He welded 2 marine engines on a raceboat that were doomed to failure. The boat didn't make it out of the harbor when BOTH crankshafts failed!
Really nice job, it's good to see real tradesperson doing a proper job. I work in maintenance shop and it is very hard to find a good machinist. Keep up the good work!
Love your work great skills and articulate explanations well done!!!
Randomly found this but was fascinated and loved every minute till the end. Thank you
That spray welding always looks amazing.
I used to work for Qantas Engineering and it was common to do plasma spray repairs on 747 engine parts. We even had a plasma spray robot that would take parts up to 8 feet in diameter. Sadly all that world class engineering facility has now been shut down and all that expertise has been lost.
All shipped offshore to save a few pennies, Thanks Alan
There lays the issue... If you really want to America Great Again then bring it Home... We have to atary teaching the youngster how to do things again before it is too late... Yhe past 6 weeks should teach them something about when something hugh takes place and you have to rely on other countries to make basic things like gloves and mask for you... what if they refused.
@@dperson6557 Qantas is an Australian company and is based in Sydney not America
⁹9
Isn't that the truth our government shut down the worlds best steel products. I lived in Ohio and all huge steel mills along the Ohio river shut down. Pennsylvania Michigan all ghost mills
Very well done video. Thank you for sharing. Very interesting procedure.
Normal machinist: "You can remove material but you can't add on material"
Abom79: "Wanna bet?"
300! Seen em all! Really enjoyed the explanation at the end. Thank you and God Bless.
Wow what a pleasure to watch someone work that knows what the hell they’re doing.
So, I know absolutely nothing about welding, but I completely enjoyed watching your skill! You rock sir!
This shows an artist at work - that's where the word ARTisan includes specialists like this man. Well done!!
Love seeing old techniques still being used in modern times. Time is money to everyone and spray welding done right will save a lot of time and bring in a lot of customers. Well done!
Not just fixed, it's cleaned up from top to bottom. Lots of pride in your work there and I admire that.
1
Mate that was great. Never seen the spray transfer process. Very interesting indeed. And you and the Missus make good videos.
As a retired Craftsman, it is heart warming to see a Master at his Trade..Thankyou for sharing..God Bless..
FYI, if your fingernail catches on something, that something is .003" thick or more. Under .003, your fingernail won't catch. That's a masters level biotech engineering "rule of thumb".
Randomly stumbled on this video. I have zero engineering / technical skills and still had fun. I'm not sure if I enjoyed the technical demonstration or your camera presence and dialogue more. Keep it up.
I have absolutely no idea what you are doing, but it is fascinating
I am beyond impressed by your level of expertise and craftsmanship. Utterly fascinating seeing this hidden world. You are truly an awesome example as to why we should encourage young people to consider trade schools and the like.
In the 1950s I was a 17 year old machinist mate in the after engineroom of the USS Kearsarge, CVA33, an Essex class aircraft carrier. Because I was rated (schooled), I was allowed access to the ship’s machine shop where I developed skills with a lathe and even a shaper. All the guys in this compartment were old salts and mostly interested in lounging and drinking coffee, but I loved making things here when I was not on duty in the engineroom. I began getting jobs making aircraft parts and things for the two galleys. Loved it all. I used many of these skills later when I became a jeweler. You seem like me in the sense you obviously love and enjoy your work. I was NEVER close to being as good as you, though. Thanks for the channel.
Adam, that footage that Abby took was sharp as a razor, keep up the good work. Glad you were able to go independent in your family machine shop.
That repair is really cool. Nicely done
Cool...and them goggles are so steam punk....lol
This is the stuff about machining I always enjoyed, fixing random stuff. Maybe someday when I'm too stoved up to keep logging I'll get me a mill and lathe and spend my retirement tinkering with stuff. 25 years machining, did it all, but they don't want experience anymore they wan't grunt labor, so back to the woods I go
I'd love a colaboration with the slow-mo guys of some of those spray shots (22:00). Would be fascinating to see the powder turn molten and stick
I second that
You are a great presenter! That's a great skill beyond the machining. One of the best RUclips videos I've seen on any subject. Good job.
I worked in factories where we occasionally had shafts spray welded but I never saw the whole process up close.
I stumbled upon this video and I gotta say, you've just earned a new subscriber.
That's a pure joy to watch you work.
Thank you and keep it up :)
I don't comment on many videos but I must say you have a great way of explaining and demonstrating your craft.
Never knew there was a process as spray welding, great vid and a great job on that!
I'm glad almost 2 years later this video is getting a lot of attention. These processes are VERY interesting and amazing to see. thanks for filming this!