The Theory of Welding and Industrial Accidents

I'm not going to predict why industrial accidents happen, I'm only going to say this is a beginning welder's mistake and this is an experienced welder. Please don't come to this channel for your welding advice, merely giving this as context for how to think about welding. There are welders out there who literally have no idea what they're doing, and that's not okay.

As someone who has owned a MIG welder for 35 years, I can tell you that it's been working fine for me. I follow the settings and instructions that come with it, but I'm not a certified welder. I'm just a guy who's learned through trial and error how to get the job done. But that's exactly why I want to share my experience with you today.

When working with welding, there are many potential problems that can arise. One of the most common issues is the repeated movement of parts that put too much pressure on one spot, causing it to slowly work itself loose over time. This can be especially problematic in situations where there's a lot of leverage involved, as I mentioned earlier.

To solve this problem, I needed to find a way to distribute the weight and pressure more evenly. One solution is to use a grinding tool to create a slot or groove in the metal that the welder can fit into. This will provide a deeper hold and more reliability, especially when working with industrial materials.

I started by taking my grinder and carefully grinding out a slot about halfway through one of the pieces of metal. I then welded into that channel, creating a strong and stable connection. By doing so, I was able to maintain the structural integrity of the piece while still addressing the problem at hand.

However, I soon realized that I needed to repeat this process for all four sides of the attachment. So, I took my grinder and carefully ground out another slot in each of the remaining pieces, before welding into those channels as well. This ensured that all four sides were secure and evenly supported, providing a strong foundation for the rest of the project.

As I worked through this process, it was clear that attention to detail was key. I made sure to grind down any rough edges or surfaces that could interfere with the weld, and then carefully laid in a bead of weld on each side. By doing so, I was able to create a smooth and even surface that would provide long-lasting support.

One potential issue I encountered during this process was the fact that I forgot to turn on the gas before welding. However, thanks to the remaining gas in the system, I was still able to complete the job without any major setbacks.

Upon completion of the project, I took a step back and admired my handiwork. While the repairs may not have been perfect, they were at least functional, and that's all that mattered. And as someone who has experience working with industrial materials, I can tell you that sometimes it's okay to make mistakes – as long as you learn from them and move forward.

In conclusion, welding is a complex process that requires attention to detail, patience, and practice. While this may not have been the most elegant solution, it was one that worked. And by sharing my experience with you today, I hope to inspire others to take on their own projects and push through any challenges that come their way.

For those who are interested in learning more about welding or industrial materials, I encourage you to check out our merch store. We're always updating our roster with new products, including tested mugs, hats, and cups of tea. And if you've already been to the site before, we appreciate your continued support.

Thanks again for joining me on this little project, and I'll see you in the next video!

"WEBVTTKind: captionsLanguage: enforeign Savage in my cave uh with a friend request I was having dinner with my friend Tracy the other day and Tracy was telling me Tracy you might remember from the uh cat Wheel video Tracy is your dad uh we fixed her large four foot diameter cat wheel for her ludicrously active and insanely beautiful cats a few years ago there's a link in the description anyway I was having dinner with Tracy and she said that her bed squeaks and that uh they localized the problem to the hardware of the bed and I thought it was I'm gonna fix this for her because they ordered new hardware and she asked me how do I stop it from squeaking she said I expected it'll fix the squeaking in the beginning but that if the hardware is built the same way as the old Hardware the squeaking is going to show up again and it's literally like waking them up when one gets up in the middle of the night to go to the bathroom and that's no good so how do you stop the bed from squeaking well beds are you beds are an interesting engineering structure because uh they are very much in industrial beds exploit our weight for stability that is if you've ever tried to lift a modern bed and had it all twisty on you because it doesn't like beds are like cats they don't they don't like being in another orientation um and the reason is really specifically because of this and this is very much how beds are built all over on an industrial scale uh this is a uh this is half of the hardware uh so a bet is a four parts there's a head and a foot and then there's two rails that go between them that is almost every bed in the world and on the ends of the Rails the two long rails that go up the bed uh on at each end is something like this uh a little piece of metal that screws into the rail and fits into two corresponding slots and if you can see here there you go so the slots are made out of the same metal and you can see it doesn't quite go all the way up in there and that's by Design the slot this will go through the slot I'm sorry I don't have the slot you're just gonna have to picture it in your head the slot will go this will go through the slot like this and then because it's the same amount of metal the same size of metal the slot will end up providing a wedge fit that this will as you lie down on it it drives these parts together right it's like your weight gravity is what provides stability a really terrific uh example of gravity induced stability are traveling masseuse tables my ex wife was a masseuse and had a massage table and they are marvels of engineering because they're light enough for a person to carry and then when you unfold them a series of spindly legs and thin cables yield this absolutely Rock Solid structure as long as you're standing on it um that's a terrific example of a of a gravity enhanced a structure that gravity enhances its strength so let's talk about Industrial Automation and parts these these metal tabs these these uh pill-shaped long pieces of metal these are stamped and actually you can see the edge artifacts of their stamping um they're punched so there's a punch that is this shape and a corresponding hole that is this shape and a piece of sheet metal goes across in a punch Tonk punches out these plates uh and then these countersinks they don't even look like they're drilled they look like they're also punched or something uh yeah it's hard for me to tell whether they're gonna skip you let's give you some b-roll all right so here we go so this Edge detailing that is a really clear evidence that it has been punched and not cut um yeah you can kind of see that sort of dividing line that's like yeah so this there's a hole that is this shape and a punch that is also this shape minus just a tiny bit and it comes down and punches it out of the sheet metal and then the same thing goes for these little ears the ones that uh the ones that will wedge into the slot on the other side of the bed these ears are also punched and you can see that they're punched this is another evidence of punching that that rounded top and the flat bottom um it was punched from this side out of the metal am I right about that it could be that it's punched out of the side okay uh so uh I'm actually not sure which side let's punch it out on so sorry I don't have that institutional knowledge hey when you want the Deep institutional dive into this kind of thing you can go to Ave that's not what I know how to do but so uh these little ears are also punched and um why do they squeak well because these aren't welded together they are not welded together so what happens is this is punched and it has a little tab on it little Tab and you can see you can see the end of the little tab oh you can see the end a little tab there and that comes up through a hole here and it's a little bit proud that is it's probably about fifty thou taller than the receiving plate and to attach them permanently side note can I tell you one of the great jokes that my partner uh misses don't try this Julia came up came out with uh when we were first dating it was like third fourth date where we're completely uh over the moon about each other already by the third or fourth day and um I want to say something pithy and funny and so we're out at a a bar in Berkeley that has board games and we're playing some board games and I said you know I've been doing this with my air coats forever but I was actually thinking of switching to this instead of this I just feel like this is more has more conversational weight than this and Chilean goes oh you're switching from serif to Sans serif air quotes I love that one of my favorite jokes ever yeah uh I'll never be that funny anyway um so uh these are these uh little uh leaves tabs ears are attached to the base plate per manently uh by a machine that comes by and goes it's effectively like a pressure rivet it's not a these are not one thing when you weld something you are making two things into one thing into one actual material you are joining materials that's why a weld Bond glue is called a weld Bond because it melts both sides and brings them together and steel welding aluminum welding all that does the same thing this is not welding this is uh riveting but like a notch down from riveting and so over time that connection can loosen that's I understand how late stage capitalism works I'm still endlessly disappointed by it uh so we're gonna fix this for Tracy um and we're gonna do it uh we're gonna do it I'm actually in a pretty simple fast straightforward way um I'm gonna weld it but I'm not just gonna weld directly across that because uh when you weld you actually if you take two things like uh let's see so when you have two objects like this and you want to weld them uh it is certainly doable to weld like that but your the weld's only going to go down to about there and maybe down to about there and that's do you see the problem with this you're adding some structure but it's like a false it's like a false structure let me show you how you really want to do it so when you're welding two bars together what you really want to do is you really want to um you really want to cut out you want to grind out a chamfer like this and so you have that space and then when you weld into it you end up with a weld that comes down like that and to be fair like when they build submarines and stuff that chamfer goes like deep and those welds are many it's not just one it's like four five six I don't know how many welds they do plate to plate but you you understand like right so we're just we're getting a lot more strength out of this equation because we're bringing the weld farther towards the center of the bar and the more strength you want the deeper you grind and the more you fill um that's the theory of welding right so this is what this is whenever you read about like an industrial Act I am not going to predict why industrial accidents happen I'm only going to say this is a beginning welder's mistake and this is an experienced welders and please don't come to this channel for your welding advice merely giving this as context for how to think about welding there are welders out there I literally I am not a welder I have a welder I own a MIG welder which is just like a glue gun that sprays steel and I look up the settings and I you know follow what it says and I've been doing that for 35 years and it's been working fine for me but I am not a welder I'm not certified I all the stuff about Metals for this this is this is literally like the the most basic first day learnings of welding but I point this out to talk about how I'm going to solve this problem because if I just weld it over the top of this um I still end up with a structure in which there's an attachment down here but this still has a lot of Leverage with which to rock against this and that's already the problem is the amount of pressure happening and the repeated movement it's causing this to slowly work itself loose and if I weld on the bottom there I'm I'm welding at the farthest point from the end of the lever arm here and I want to go in a little bit I'll get more permanence I'll get more reliability I'll get a deeper hold if I go a little deeper how am I going to go deeper what I'm going to do is I'm going to take a grinder and I'm simply going to grind a slot like this about halfway through this piece of metal here about halfway up here like that there we go I'm going to grind it did I put it in the wrong spot there we go I'm gonna put it in about halfway up this piece of metal there and then I'm going to weld into that channel that's what I'm going to do so I still get the holding power of this like rivet whatever that's called tell me in the comments please with that kind of industrial pressure joint is called I still have some holding power on either side of the equation so it's not like I'm grinding out these and trying to put them back in and it's also not I don't want to weld in here because this goes right up to the plate that it meets so I need that square corner of up here so yeah I'm gonna I'm gonna set these up on my Vise grind out slots in each of these four take them over to my welder lay in a bead on both sides grind it down a little bit and I told Tracy that they may have to just do a little bit of Excavating on the end of the bar to accommodate that but uh that that should take care of the problem yeah here we go there we go okay this is indicative of what I'm talking about see that ground down in the middle there I'll lay a weld bead in there and all will be Jake let's uh grind out the other seven and then we'll go over to the welder there we are they are all they are all ready let's go to the welder foreign that is because I forgot to turn on the gas that still looks okay because of the remaining gas in the system here but not there whoops all right yeah I gotta grind those out and redo it go foreign T pretty it'll do the grinder foreign I have my slightly ground but nicely welded new bed uh new bed attachments uh one thing you could see is oh it's not quite straight it's not quite straight so we're gonna fix that with just a little bit of um and we'll work excellent okay so now I want to make sure I don't have anything sitting up on top there let's see here these are not pretty repairs but that's because they're never getting seen sure nice and oh all right hopefully uh Tracy will send me a picture of these installed but uh that's just a little bit of uh it was a little kind of the engineering problems I solved for my friends uh thank you guys for joining me for this very quickie little thing and uh hopefully this is a shot of the bed frame actually going back together all right thanks guys I can't thank you enough for supporting us by watching the channel if you've been to our merch store you might want to head there again because we are always updating our roster with new products here is the anime inspired tested logo in Japanese my one of my all-time favorite new designs uh we're also selling tested mugs and tested hats oh and if you want a cup of tea we're selling that too Tessa dashboard.com tester.store.com okay foreign\n"