You can't win them all, good idea on ultrasonic pre machine inspection.

I have to say that you are "MULTI-TALANTED!!" Opening a shop on your own, doing what you do, requires "TALANT". some things can be learned but sone comes with intuition. I my opinion, you have both. i could open a shop but do not have the talent to be able to do all the different things that you do. I also admire how you will not do a halfass job. All your work is top notch (EXCELENT). This is why you are busy.

Very interesting video. You are an exceptional machinist. I had to produce videos with narration and was informed that I started to run the narrative together with “ah’s and um’s, something we should catch and correct, if that is happening.

I like the pre heat table, that's a good idea 👍

Those wheels look like a good candidate for a hub with a shrunk on 1/2" thk steel tire. Tire could be 4140 or such to be harder yet still replaceable. You should offer that product to them as an upgrade.

I don't understand what problem there was during the welding phase... but I really have to say that you're really good at machine tools 😉👍

It is amazing that the damage came to the surface with the final cut

When I saw your helmet fan I thought it could pick up a fart and sure enough your answered my question. I do not know anything about the different kinds of steel but how do chunks fly out? Was it impurities in the casting? It is to bad that you found more and that it is not repairable. Good to see you and the video this morning.

Also, the comment of steel tire is even better to the rewelding option.

Send it to Harper Corp. of America Charlotte NC

Liquid penetrant inspection only indicates voids that are open to the surface, but it's quick and relatively convenient.

Josh:

Could you send it out for X-ray to see how bad things are before scrapping it? Might be a candidate for powder welding, or whatever Adom70 does.

I was wondering if the fail/surprise was going to be the entire cap getting caught in the cutting tool and all it a major portion of that peeling back off the wheel. Is there a reason that a shrink fit cap cannot be made and press fit over it? Or would the material hardness needed for the cap not be compatible with sweated, or heated and the wheel chilled to do a light press fit if a new outer cap surface?

the Miller [FS filter] Hilarious....I am not sure if the 70s-3 is softer than the 70s-6 wire, the 70s-6 has more silicon as a deoxidizer and slightly more manganese. the S3 has 26% elongation compared to S6 28%. the Charpy V notch for S3 is 87 ft lbs at -20 degree f and S6 is 71 ft lb at -20 f...this is data from Lincoln Electric for their Superglide series of wire as welded. 70s-3 applications are pipeline, pressure vessel and structural, while 70s-6 is automotive repair and structural and medium to heavy mill scale material while 70s-3 is for clean to light mill scale material. ....both are recommended for sheet metal....tensile strength with co2 is 74 ksi for 70s-3 and 78 ksi for 70s-6, those are as welded figures.....hope this helps, cheers from Florida, Paul...great video on this repair.....even though it blew up in the end!!!!!

Josh could you have welded a harden sleeve on it and turned it down smooth or does the diameter come into play then. I've never had the opportunity to work on a trommel.

Are those holes, voids in the casting during manufacture?

This is classic rolling contact fatigue damage caused by a combination of overloading the surface of the wheel and very poor material with excessive inclusions. You had no chance, and in my view, this was always going to happen at some point. to be honest I am not sure what re-skimming would do except even out the surface stresses and it may be that the heating cycle of the welding process may have been a contributing factor. But as I said you really had no chance with this wheel.

What ever happened to Keith fenner from New England

I know its been long time since you recorded this Fail attempt. Did you ever think of putting a steel band up to the right size required if you could lathe the cancer out of the wheel. And bolt 🔩 it on the wheel an have a few key ways to also help it from turning if any bolts broke. I'm not a engineer but I'm sure you could do something like this and if band was damaged you could either replace or lathe till needed replacement. If you get more like that why not try. And if this one is still around why not try and do my idea if possible. Good luck