Shitty welds don't matter huh?

[synapse]

Hey guys, thought you'd find this interesting.

One of the test rigs I have setup for testing our wastegates applies high amplitude vibration, and at different vector angles, and some setups designed to amplify the effect of gravity.

One of the guys that isn't a welder, but just learning, welded this rod to the flange just so that we could test the part. And only after about 10 hours of high amplitude cylcling, the area around the weld cracked. So, proper heat control and penetration is very important with welded parts. Buggar welds are no joke. And, this isn't even under any heat.

[87mike]

That's not even a weld.
Fail.

[nohook]

watch out jimmy will want to try his richard on that test !!!!

[2stroke]

with all that high dollar badass stuff, nobody there can even weld?

[Matt Hill]

I'm a bit confused as to how that test is supposed to work after looking at how it's been set up and welded on like that...

[b(.)(.)st_Master]

Originally Posted by 2stroke

with all that high dollar badass stuff, nobody there can even weld?

Read the post he said its someone learning to weld. Second my guess is the guy didnt heat the cast up while welding the steel to it.

[LPRacing]

umm thats a v band flange not cast

[72chevy2]

that looks more like a braze then a weld

[b(.)(.)st_Master]

Originally Posted by LPRacing

umm thats a v band flange not cast

oops my bad quick glanced it your right thought it was straight to the gate

[LPRacing]

is that bubble gum?




i dont understand this test honestly, your just testing the wastegate for vibrations of your checking someones weld? wouldnt it be better to simulate it off of thinwall stainless tubing to get all the vibrations to it, that bar looks mighty thick to simulate anything

[mufflerguy]

Looks to me like you don't have that piece supported properly. With all the weight hanging off that average looking (at best!!!) weld, of course it would eventually fail.

[FOWLER]

Originally Posted by mufflerguy

Looks to me like you don't have that piece supported properly. With all the weight hanging off that average looking (at best!!!) weld, of course it would eventually fail.

Exactly what i thought.

[synapse]

Originally Posted by FOWLER

Exactly what i thought.

Actually, the point is to generate as much vibration to the piece as possible to try to make parts of the wastegate fail. I can move the rod closer or further from the vibrator to change the axial displacement and force.

The whole point of the rig is to make the wastegate fail. But, the surprise was the weld coming apart.

It is unbalanced and unsupported on purpose to generate non-linear force against the wastegate.

[Wade Garrett]

Originally Posted by synapse

Actually, the point is to generate as much vibration to the piece as possible to try to make parts of the wastegate fail. I can move the rod closer or further from the vibrator to change the axial displacement and force.

The whole point of the rig is to make the wastegate fail. But, the surprise was the weld coming apart.

It is unbalanced and unsupported on purpose to generate non-linear force against the wastegate.

Its not weather or not the rod should be moved closer or further from the vibrator
Its how you attach it to the vibrator. That has to be one of the most half assed ways to attach that kind of part to each other.

You could have welded that with a perfect weld, and in time it would fail. And the test was to make the wastegate fail.

[Matt Hill]

Originally Posted by synapse

Actually, the point is to generate as much vibration to the piece as possible to try to make parts of the wastegate fail. I can move the rod closer or further from the vibrator to change the axial displacement and force.

The whole point of the rig is to make the wastegate fail. But, the surprise was the weld coming apart.

It is unbalanced and unsupported on purpose to generate non-linear force against the wastegate.

But the vibration must be properly channeled directly to the wastegate. The problem with the construction of the rig appears that the energy was able to be lost in transmission by the way the rig is attached to the wastegate.