Welcome to the Carbide Processors Blog
Posted on Thursday, October 8th, 2015 at 2:39 pm.
Wood is the most commonly used material for arts, crafts, jewelry, woodworking, framing, joining, sawing, sanding & painting. Here are a few safety considerations to consider before embarking on your next project.
Hardwoods – used mainly for sculptures and furniture making.
1. Direct contact from sap found in most green wood can cause skin allergies & irritations.
2. Long term dust exposure can cause conjunctivitis, hay fever, asthma and other respiratory diseases.
3. Some hardwoods contain toxic chemicals that can cause headaches, nausea and irregular heartbeat.
Softwoods- common in furniture making.
1. Dust exposure may cause respiratory inflammation.
2. Some individuals can develop allergic reactions involving skin irritations.
Plywood and Composition Board-
1. Formaldehyde is toxic by ingestion and skin contact.
2. Machining, sanding or heating can cause formaldehyde to become airborne.
Wood Treatments & Preservatives-
1. Certain chemicals are highly toxic and can be absorbed through the skin causing organ damage.
2. Inhalation may cause digestive problems as well as kidney and blood damage.
1. Epoxy glues are toxic and should not come into contact with skin, eyes or inhalation.
2. Cyanoacrylate glues can glue skin and other materials together requiring surgical separation.
3. Formaldehyde-resin glues are carcinogens.
4. Adhesives are extremely flammable and cause nerve damage when inhaled.
5. Water based glue is slightly toxic when ingested or inhaled.
1. Toxic when inhaled or makes contact with the skin.
2. The solvents used are highly flammable.
3. Caustic soda used is highly corrosive to human skin and eyes.
Painting & Finishing-
1. Mixing paint from dry pigment can lead to possible inhalation.
2. Solvent based paints are flammable.
3. Water based paint does contain some solvents but is of minimal risk.
4. Shellac usually contains ethyl alcohol which is slightly toxic but lacquers are made up of toluene & hexane.
5. Paints, waxes & polyurethane coatings based on mineral spirits are combustible.
6. Oil soaked rags and paper towels are a spontaneous combustion hazard.
Preventive measures should always be used to maintain your safety. Wear the proper safety gear as in safety glasses, hearing protection and face shield/mask. Also, know the tools and machines your are working with. Make sure to read manuals and follow recommendations on tool care and RPM’s. Make sure all blades, bits and drills are sharp and in good working condition. Do not use a tool or attachment on a machine for which it is not designed. Always clamp stock securely when sanding, grinding or drilling. If possible, use an exhaust ventilation system to remove sawdust and chips from your machines. Work in a clean well-ventilated area and research the wood and/or chemicals you will be working with. Avoid distractions!
Posted on Friday, October 2nd, 2015 at 1:28 pm.
Today’s youth is tomorrow’s future. Tom, the owner of Carbide Processors, firmly believes this and is always more than happy to help and invest in our youth.
About a year ago, we had received an email asking for help with supplies and tools for a middle school robotics team. This request was for a group of young kids that had a strong desire to learn and were very interested in robotics and science. Of course we were more than happy to help.
The boys were eager and excited to organize their own robotics team and compete against other kids in the VEX robotics competitions. The mother of one of the students that had originally contacted us shared a letter about the team and the VEX Robotics program below.
“Last year, two of the boys, Ben and Devin, wanted to start a new robotics team in December but they were informed by their school that it was too late in the year to start a new team. They were told that they were still young, 6th graders and 12 years old, and that they could start a new team in the next school year. Well, Santa was kind to them that December and robot parts arrived under the tree. The boys formed a team outside of the formal school system: Team 351A-The Warp Drivers. The boys worked hard and competed as an independent family-supported team. Amazingly, they went on to win the Vex Robotics Maryland State Middle School Championship last year (I guess they weren’t too young to win)! This year the two boys were joined by another friend, William, also a middle school student. The three boys, now seventh graders, have repeated their winning performance in the 2014-2015 Vex Robotics season and have again won Vex Robotics Maryland State Middle School Championship! Two years in a row! Additionally they are #1 in Programming and #1 in Robot Driving in Maryland, middle school division. To watch the team in action, the boys have some of their robot matches posted on their YouTube channel (Vex351A): https://www.youtube.com/channel/UCUMnULnhHnLXjEklvBWy0_g
Needless to say, we are all very proud of our kids!
[We’re pretty proud of these young kids too]
The VEX Robotics program, which is a part of the REC Foundation (http://www.roboticseducation.org/), is an incredible program that fosters STEM in the community, inside and outside of schools. The obvious aspects are engineering and programming but it also teaches kids to present their work to adult judges and to learn to communicate with their peers, since the kids have to figure out how to work together (and against each other!) on the competition field. The 2015 VEX Robotics World Championship Middle School Division information can be found at http://www.robotevents.com/robot-competitions/vex-robotics-competition/re-vrc-15-1983.html. It will be held in Louiseville, Kentucky at the Exposition Center and at the same time, the Elementary, High School, and University divisions will also be running. There will be over 4,000 kids from all over the world competing …. and about a zillion parents and teachers will be present!”
Elizabeth thanked us for our “generous support”, but we were truly grateful and honored to be able to help out such a great program.
The VEX Robotics teams often use hex keys (like the Bondus 5/64″ hex keys, or the Bondhus 3/32″ hex keys) to construct their robots. We had made a donation of hex keys and Edge Eyewear safety glasses to the kids in the VEX program. Thank you Elizabeth for sharing your story and for allowing us to be a part of it.
Posted on Tuesday, September 8th, 2015 at 1:52 pm.
Below is a chart taken from Wood Magazine on recommended speed rates for various types of drill bits. Please note that NR means Not Recommended.
|Recommended Operating speed for the given material|
|Drill Type||Soft Wood||Hard Wood||Acrylic||Brass||Aluminum||Steel||Glass & Tile||*Shop Note:|
|Twist Drill Bits|
|1/16″ to 3/16″||3000 RPM||3000 RPM||2500 RPM||3000 RPM||3000 RPM||3000 RPM||Lubricate drill with oil when cuttin steel 1/8″ or thicker. Use Center punch on all holes to prevent drill from wavering.|
|1/4″ to 3/8″||3000 RPM||1500 RPM||2000 RPM||1200 RPM||2500 RPM||1000 RPM|
|7/16″ to 5/8″||1500 RPM||750 RPM||1500 RPM||750 RPM||1500 RPM||600 RPM|
|11/16″ to 1″||750 RPM||500 RPM||NR||400 RPM||1000 RPM||350 RPM|
|Brad Point Bits|
|1/8″||1800 RPM||1200 RPM||1500 RPM||NR||NR||NR||Raise 1/4″ and smaller bits often to clear shavings and prevent heat build-up.|
|1/4″||1800 RPM||1000 RPM||1500 RPM||NR||NR||NR|
|3/8″||1800 RPM||750 RPM||1500 RPM||NR||NR||NR|
|1/2″||1800 RPM||750 RPM||1000 RPM||NR||NR||NR|
|5/8″||1800 RPM||500 RPM||750 RPM||NR||NR||NR|
|3/4″||1400 RPM||250 RPM||750 RPM||NR||NR||NR|
|3/8″||1200 RPM||250 RPM||500 RPM||NR||NR||NR|
|1″||1000 RPM||250 RPM||250 RPM||NR||NR||NR|
|1/4″ to 3/8″||2400 RPM||700 RPM||NR||NR||NR||NR||Raise 1/4″ – 3/8″ bits often to clear shavings and prevent heat build-up. Make several shallow passes with larger bits; allow bit to cool between passes.|
|1/2″ to 5/8″||2400 RPM||500 RPM||250 RPM||NR||NR||NR|
|3/4″ to 1″||1500 RPM||500 RPM||250 RPM||NR||NR||NR|
|1- 1/8″ to 1- 1/4″||1000 RPM||250 RPM||250 RPM||NR||NR||NR|
|1- 3/8″ to 2″||500 RPM||250 RPM||NR||NR||NR||NR|
|Glass & Tile Bits|
|1/8″||NR||NR||NR||NR||NR||NR||750 RPM||Wear safety goggles. Use drill press only. Do not apply excessive pressure. Lubricate with water while drilling. Reduce quill pressure when bit tip emerges from back side.|
|1″ to 1- 1/2″||500 RPM||350 RPM||NR||250 RPM||250 RPM||NR||Do not use with brass or aluminum thicker than 1/16″. Avoid dense hardwoods such as maple.|
|1- 5/8″ to 2″||500 RPM||250 RPM||NR||150 RPM||250 RPM||NR|
|2- 1/8″ to 2- 1/2″||250-500 RPM||NR||NR||150 RPM||250 RPM||NR|
|2- 1/8″ to 4″||250 RPM||250 RPM||NR||NR||NR||NR||Smaller sizes also available; use Forstner speeds.|
|1/4″ to 1/2″||2000 RPM||1500 RPM||NR||NR||NR||NR||Clamp work to table to improve quality of hole|
|5/8″ to 1″||1750 RPM||1500 RPM||NR||NR||NR||NR|
|1- 1/8″ to 1- 1/2″||1500 RPM||1000 RPM||NR||NR||NR||NR|
|1-1/2″ to 3″||500 RPM||250 RPM||250 RPM||NR||NR||NR||Drill one side, flip material over, place center bit in it’s hole and resume cut|
|3-1/4″ to 8″||250 RPM||250 RPM||250 RPM||NR||NR||NR|
|2- flute||1400 RPM||1400 RPM||NR||NR||NR||NR||Raise and lower frequently for quicker cutting|
|5- flute||1000 RPM||750 RPM||750 RPM||250 RPM||250 RPM||250 RPM|
|Countersink screw pilot bit|
|All Sizes||1500 RPM||1000 RPM||500 RPM||500 RPM||NR||NR||Clear Twist often|
|Any||1000 RPM||500 RPM||NR||NR||NR||NR||Cut to full depth so bit chamfers plug.|
Posted on Tuesday, September 8th, 2015 at 10:58 am.
We are happy to announce our new partnership with Chapman Manufacturing (Chapman Tools) located in Durham, Connecticut. John Chapman started the business in his garage during the Great Depression in 1936. Probably not the most ideal time for a new business venture, but through hard work, superior hand tools and outstanding customer service Chapman Tools has become the leader of American Made tools using American Made materials.
Jay Leno endorse 2014 Employees
Chapman has perfected the manufacturing process of precision small screwdriver and bit kits since its conception in 1963. With innovative features such as utilizing micro- manufacturing, tighter working tolerances and non-magnetic materials, Chapman’s tools are highly sought after. Customers appreciate these superior Made in the U.S.A. tools as well as knowing that the dollars they spend go right back into the pockets of the American people. As new technology brings more computerization, mico-manufacturing and tighter working tolerances, Chapman tools are highly sought after. All Chapman tools are non-magnetic, hand assembled- inspected and available in different combinations in their tool kits.
Chapman ¼” drive screwdriver bits, are available in 53 types and sizes including Standard & Metric Allen Hex, Phillips, hollow ground straight sided Slotted, Bristol 6-flute, Reed & Prince/Frearson, Robertson square head and Torx. All are milled from USA tool steel, heat treated with a black oxide finish and are interchangeable with their screwdriver handle and famous offset midget ratchet. Two available extensions add length to the screwdriver handle and ratchet. All Chapman tools are non-magnetic, hand assembled and inspected and available in different combinations in their tool kits.
The beauty of Chapman tools lies in their versatility. The offset midget ratchet provides up to 200 inch pounds of torque (four times the leverage of a large screwdriver) in a tiny space. There’s also a screwdriver handle and a spinner top, both of which can be used independently or combined with their 2” or 3 5/8” extension. You can even use the ratchet, screwdriver handle and extension together as a ratcheting screwdriver.
While there are many types of insert bits on the market, Chapman’s are reasonably priced and offer exclusive quality features competitors don’t. All the bits are stamped with a part number and have a ball-detent, which is a tiny spring and ball bearing that locks the bits into the tools without the use of magnets. The bits have ear stops or oversized working ends depending on size, and all but the Torx bits have knurled ends for finger tightening. Lastly, the bits are heat treated to a specific hardness for each size and are meant to break before damaging a fastener. For example, many gunsmiths rely on Chapman Slotted bits for working on antique firearms with irreplaceable soft, hand cut screws. Chapman tools are engineered and are hardened to specific tolerances to prevent damage when the fastener is more valuable than the bit.
Famous Midget Rachet
*1/4 drive 20 tooth steel gear
*18 degree working arc
*exceeds Military standards for torque specifications
Screwdrivers and Accompanying Bits
*economical screwdrivers with adjustable set screws
*¼” drive screwdriver bits available in 53 types and sizes
*bits are heat-treated for hardness & designed to break before damaging the fastener (gunsmiths)
*made using USA tool steel, heat treated with a black oxide finish
Other Important Information
*all tools are non-magnetic
*hand assembled and inspected not once but twice
*many combinations offered in tool sets
Chapman manufactures these for:
*calibrating & servicing of aerospace
*medical & dental professionals
*sound & robotic equipment
*knives & firearms
***Jay Leno has been a long time user of Chapman tools for his antique cars and motorcycles. About five years ago Jay invited Tracy, the owner of Chapman out to his garage in Burbank, California to film a short video promoting Chapman tools***
Posted on Wednesday, August 12th, 2015 at 12:47 pm.
Does Filtering Machine Coolant Really Matter?
Coolant Filtering Works
It Saves You Money
Filtering grinding coolant is just like filtering the oil in your car. Dirty oil and dirty coolants wear out the equipment.
Increase Machine Life – save $2,000 to $8,000 per year
The big advantage in clean coolant is that it protects the machine. Dirty coolant can shorten machine life by 5% to 7% a year. Saw and tool grinding generates a huge amount of very small, very abrasive particles. These particles get into the coolant and then are sprayed all over. These particles get into controls, cylinders, rods and bearings where they increase wear and reduce quality. The CP 2002 removes particle down to one micron and removes them with incredible efficiency.
Particles per cubic centimeter: Unused coolant Dirty coolant Filtered coolant
11,885 76,299,682 40,000 to 100,000
96% to 99.9% particle removal
Longer Coolant Life – save $1,000 a year per machine + the saving in labor
If you filter your coolant you will get much longer life. In actual tests we see coolant last six months and it is still doing an excellent job. This saves you on coolant costs and the maintenance of sump cleaning and coolant changing.
Reduce Diamond Wheel Costs – save $3,000 to $10,000 per year
A good grinding operation will still dump huge amounts of oil and grease into the sump. We ran a test on a high production machine. In twenty-two days of double shift we pulled out about ten pounds of oil and grease. This oil and grease clogs the wheel. Clogged wheels mean slower grinds, worse quality and shorter wheel life. Clean coolant increases diamond wheel life by at least 30% overall and as much as 50% depending on the wheel and the application. This is saving of 25% to 35% in annual diamond wheel cost. (Tests run in Feb. & March of 1998. Six dry filters weighed 5.45#. Six dirty filters drained of water weighed 15.21#. The difference was 9.76 pounds.)
Removes oils and greases
Very Low Filter Cost
The CP 2002 comes with replaceable or cleanable filters. This is a low cost unit that is very effective. If you are concerned about the true cost of the unit then the CP 2002 is a better buy. The CP2002 runs a month without filter changes because it ran over a month of double shifts in repeated tests in an actual saw shop. We ran tests for two weeks and they worked. Then we ran tests for a month and they worked. Finally we wanted to run tests until the filters clogged up. It took 22 days of double shifts before the filter clogged up. The filters worked well all month. (We tested dozens and dozens of filters to find the right combination. If you use the wrong filters your performance can drop from weeks to days or hours.)
Filter Cost $24 a month and only one filter change
Our Units Do Not Harm Coolant
Building a filter system right is very difficult. It must take out tramp oils and greases without taking out the lubrication and anti-rust from the coolants. In addition to particle count we also tested for turbidity, pH, viscosity and conductivity. In all four areas the filtered coolant measured the same as brand new coolant.
|Unfiltered||New||1/2 Hour||11 Days||22 days|
Our 23 Top Reasons to Filter Coolant
1. Longer Machine Life
2. Longer time between rebuilds
3. Less down-time
4. Less equipment replacement
5. Faster operation
6. Faster cycle times
7. Fewer wheel replacements
8. Smoother grinds
9. No burning
10. Cooler grinding
11. Longer coolant life
12. Longer grinding wheel life
13. Less machine maintenance
14. Less dressing required
15. Perhaps increased operator safety
16. Retards bacteria growth
17. Eliminate smells
18. Less OSHA exposure
19. Less EPA exposure
20. Less waste
21. Cleaner waste
22. Lower coolant recycling costs
23. Turn an expense into income
Posted on Tuesday, July 7th, 2015 at 3:51 pm.
We are always looking for ways to make cool stuff with out tools. But, how about making cool stuff out of tools! A scupltor in Australia has found a new life for old, rusted wrenches that would give Michelangelo Buonarroti a run for his money. Not sure who Michelangelo Buonarroti is, you might recognize his work by the picture.
John Piccoli began creating his sculptors over 30 years ago for his small garden by using the wrenches he had collected. Fast-forward to today he is creating large statues and museum quality art pieces in Sydney and Melbourne, Australia.
Not only is John extremely talented, but he is also a Polio survivor who has been wheel-chair bound since 8 years old. You may wonder how he is able to create these sculptors that are life-like in size and shape!
John’s custom workshop is can work in 3 dimensions with the use of a cross-over gantry crane and several block and tackles at allow him to work at chair level.
Hopefully looking at these pictures will help inspire you to create something beautiful out of un-used tools! We would love to see what you come up with.
Posted on Thursday, June 4th, 2015 at 8:13 am.
It’s coming up on that time of the year again. The time of year that we rack our brains trying to figure out what dad really wants and then finally settle on a “Best Dad” coffee mug or another blue tie. Why not really surprise dad this year with a gift that he can really use and will actually love. We’re not saying he didn’t love the “Best Dad” coffee mug, we’re just saying it may be time to change things up and really surprise him with a gift that will have him thinking of you every time he uses it.
We have some great gift ideas for the DIY Dad’s out there. Whether it’s woodworking tools for the shop or hand tools for around the house, we have some great gifts that will make Dad’s day special without breaking the bank.
1. I have too many clamps… Said no DIY Dad EVER!
We have great deals on Clamps from Bessey Tools or Woodpecker. These clamps are sure to make working on his next project a breeze. Everyone knows when working on bigger projects, 4 hands are better than two. Clamps will help Dad finish his projects faster and with ease. Give Dad some Bessey clamps to help free up his hands and his time. We recommend our most popular selling Bessey clamps- The Bessey K Body Revo Jr, starting at just $63.11* for a pair.
*These are current prices as of June 2015. prices may vary over time.
2. Give your Dad a hand, or protect the ones he has…
Give Dad a cutting edge on all his woodworking projects while keeping him safe with Micro Jig’s Push blocks. Micro Jig makes the most innovative products that give more precise cuts while keeping the user’s hands safe from sharp and dangerous woodworking equipment like table saws and routers. If the Dad in your life is an avid woodworker, then Micro Jig’s push blocks are sure to be on his wish list. Micro Jig GRR-Ripper push blocks are starting at $24.95* or upgrade to the 3-D Push Block system with advanced features for only $59.00*.
*These are current prices as of June 2015. Prices may vary over time.
3. If there’s not enough room in the tool box, then It’s probably just time for a bigger toolbox.
If your dad would agree with the above statement then why not shop our Wiha Hand Tools. Save on all hand tools like screwdriver sets, wrenches, socket sets, pliers, cutters, and hex keys. All our hand tools are made from quality steel, are ISO certified and guaranteed to last. Give Dad tools he can count on as much as you count on him. Psst… Shop our Sale Section for great prices on great tools that will have you and Dad grinning from ear to ear.
4. “That’s not a knife, This IS a knife”
If your dad shares the same warm fuzzy feeling for sharp objects as Crocodile Dundee, then a SOG knife may be right up his alley. SOG is located in Lynwood, WA and makes absolutely incredible knives and multi tools. SOG got their start by making knives for the Navy Seals and Special Forces. They have greatly expanded their line of knives for use in hunting, tactical and outdoors. Outfit your Dad or your favorite everyday hero with a SOG Knife or multi tool. Want to make it even more special? Get your tool engraved with his name or a special message just from you.
5. Eat my dust… Saw dust that is.
If the Dad in your life spends a great deal of time with his router or table saw, he might really enjoy a new Router Bit set or Saw Blade. Save on American made Router bits and router bit sets that will keep dad happily making his woodworking plans come to life. Or bring new life to his table saw by getting him a brand new saw blade.
6. Needs more Power…
Is your dad is a tool lover that can’t get enough power? Give Dad a Power Tool from Triton. Triton Power tools makes award winning routers, laser-guided circular saws, cordless drivers, and more. The Triton 20V Impact Driver will satisfy the Tim the Toolman Taylor inside any Dad and will complete all his DIY projects inside and out. Choose from many other great Triton Power Tools all at very competitive prices.
7. Seeing Red…
If precision and quality are at the top of Dad’s list for the tools he buys, then he’ll love the Woodpecker’s router Accessories product line. Woodpecker’s precision Squares and layout Tools are precision ground on state-of-the-art machinery using aircraft grade aluminum steel and anodized in Woodpecker’s trademark red coating for superior tool protection. Woodpecker’s can outfit Dad’s shop with every router accessory he needs, including router lifts, rules, straight edges, clamps, and many other innovative tools that make dad’s projects easier and fun.
If you are pretty crafty yourself, why not make something for Dad. Gifts made by you are always extra special. Dad will appreciate the time and thought that went into it, even if it looks like this…
Posted on Tuesday, June 2nd, 2015 at 11:47 am.
Custom Replacement Portable Saw Mill Blades are now available at Carbide Processors. We have taken into consideration your demand for superior quality as well as affordable pricing and now offer our saw blade expertise in creating your Replacement Portable Saw Mill Blade. By combining over 30 years experience in the woodworking industry as well as using the very best materials, our custom saw blades and tooling meet and beat our customer’s expectations.
5 Tooth Replacement blades for the Portable Lucas Sawmill.
Bore & Pinhole: 30mm, 5+5 pins
Kerf: 4.8mm unless otherwise specified
Plate: 3.2mm unless otherwise specified
The Replacement blades can be made to your specifications for Diameter, as well as plate thickness and kerf. Please call us for pricing and lead time or fill out the Replacement Portable Saw Mill Blade form.
Special Offer :
**Buy a custom Replacement Blade for the Portable Lucas Sawmill and receive the Sawmiller’s Guide to Troubleshooting, or Miners Manual of Saw Hammering and Filing at a bundled discount!** Ask your friendly customer representative for details.
The Carbide Processors team continually strive to offer you products and services that you need at the best price without sacrificing quality. The custom tooling (manufacturing and sharpening) and saw blade services (manufacturing, re-tipping, sharpening, and repairing) are backed by a 100% satisfaction guarantee. We also specialize in brazing materials, brazing services, as well as special grades and sizes of carbide.
To create a quality tool you need the right materials. We have them. A minor difference in alloy chemistry can make a difference of 70% or more in bond strength and joint performance. We have done extensive testing to know just the right alloys to use and what applications to use them for. Our brazing services are patented with proven fracture prevention technology. We have been an industry leader in brazing for over 20 years and have pioneered new brazing techniques that are more fracture resistant and simply improve the quality of the tools. Our exclusive patented techniques prevents gaints, tool breakage, and creates stronger brazed joints. Choose from over 5,000 different grades of carbide including our Super C grade and our Cermet grades.
Posted on Monday, May 11th, 2015 at 12:20 pm.
A gentleman posted on Practical Machinist looking for brazing information on his failed attempts at brazing steel-to-steel and get “away from messy stick welding”. Using 56% silver and Harris paste flux with 1100-1700 working degree temperature, he was using a propane torch to braze a steel nut to a washer.
….I will admit, that out of experimentation I have heated the part to bright RED to see if I can flow it further out….it doesn’t work well and….I found that the silver seems to….how can I say this….”peel” off the steel when struck with a hammer….HARDLY MIG weld strength (as it is supposed to be). I cannot let the base metal melt the silver, I must use the torch heat directly on the rod AND the part…sometimes the flux turns black, and I must wire wheel it to clean it off, and then start again…each time losing more and more precious silver rod.
Here is Tom’s response:
Cleanliness, cleanliness. Always start with cleanliness when there is a brazing problem. Welding is pretty much a physical joining. Brazing is much more a chemical process. A really good braze joint will have both chemical and physical joining.
People do use solvents, such as acetone and similar, to clean before brazing however there definitely are residue issues as mentioned above. The advantage with something such as a soap or detergent, oven cleaner and Comet were mentioned, and they break the oils and greases down into easily removable soaps.
These are some mild steel bars I use for brazing tests. The come with scale on them. I use a bench grinder to get them clean and bright as with the right end of the top one.
A braze alloy with 56 in the title is a 56% silver braze alloy with the rest being copper, zinc, a little nickel and maybe a little tin or manganese.
We ran Charpy impact tests at Weyerhaeuser to find the best braze alloys for sawmill saws. The best was an Ez Flo 3. However this is not considered suitable because it contains cadmium. A 50% braze alloy without cadmium was about 30% weaker. 56% braze alloy with tin flowed beautifully but had about half the strength of the Ez Flo 3. A 49% braze alloy with manganese was as strong as the Ez Flo 3 but had poor flow characteristics.
We have these little braze kits. We use 0.062″ dia. wire which should be easier to use. The 56% braze alloy you’re using is a very popular braze alloy and may work very well for you if your parts are suitably prepared.
As was mentioned several times above need a very, very clean surface. It looks as though your parts may have been zinc coated. From your description of the process it appears as though you are turning the zinc and zinc oxide which is a largely and wettable surface.
I have a cheap wheel on a cheap bench grinder I use for this sort of thing. I grind to bright, shiny metal. Then I clean with an oven cleaner.
There are lots of fluxes in the world. Ideally your flux will match your braze alloy as well as the two parts being joined. This isn’t always that simple. We sell five kinds of flux for brazing tungsten carbide alone.
Were I trying to do your project I believe that I would cut a couple of short lengths of braze alloy and pound them flat. I would put a nice dollop of black flux on top of the bottom part. I would put the flat wire in the middle of the flux. I would cover the top with flux then put the bolt on top of the flux top part.
Heat the assembly until you see the flux run out.
You will need something to hold the parts in place and move the parts around. At 212 F the water will boil out of the flux and this can shift the parts. At about 1000 F the flux will liquefy and this can shift the parts. At about 1500 F the braze alloy will liquefy and this can also shift the parts.
This is a temporary brazing bench. I use fire bricks and stainless steel. I may not need two tiers but hot braze on stainless steel can set fire to the table top below the stainless steel.
You can build your own little oven. Fireplace bricks were mentioned above and they will work. We use bricks that are used to line kilns. They should be available from a ceramic supply store. We like these because they are extremely easy to work using a hacksaw, paring knife and similar. Do not use good tools on these as they will ruin the edge on a wooden saw in a few cuts.
Posted on Monday, May 4th, 2015 at 3:50 pm.
Both cordless drills/drivers and impact drivers can be used for similar jobs, but there are some key differences. A Cordless drill applies constant torque and tends to have a wide range of uses. Cordless drills have a keyless chuck that can accept a wide range of tools. They can be used to drill holes, drive screws and can be used with a great selection of accessories such as hole saws, rotary sanders, and wire-wheel brushes for doing a wide range of jobs. Drills or drivers are ideal for smaller jobs, as they provide great control across a range of speeds and clutch settings. They don’t have the impacting force that the impact drivers have and are better for drilling small screws or for drilling in softer surfaces.
Impact drivers look very similar to drill drivers and do many of the same jobs, but use a hammering like action and brute force to get the job done. Impact drivers use both bit rotation and concussive blows to drive screws with incredible brute force. They can be easier to use for large projects or projects that require large screws or drilling into harder surfaces. The concussive action transfers much of the high-energy torque directly to the screw, taking off some of the stress to your wrist and forearm. Impact drivers use a collet to accept hex-shanked drivers and bits. Because of the high concussive force, an impact bit that can withstand the high pressures of the impact drill are typically recommended.
While Impact Drivers can do most of the jobs a drill can do, but faster and with more ease, they don’t have quite the versatility that you can get with a drill. Using a cordless drill for small jobs and pulling out the “big guns” (aka the Impact Driver) for larger jobs or more difficult jobs you can take care of all your DIY jobs in no-time.