welding wire rope together in stock

Needed to make some simple security cables for some equipment. Kinda like what the places use for the grill, lawnmowers, etc. Just a loop on the end to attach a padlock. If they want it really bad it"s theirs, but at least make em work a bit. Anywhoooo.... Why can"t my mig weld the cable ends into nice burr-free loops? It seemed to burn through no matter what setting. Using fluxcore wire on MM Challenger machine. Do the individual strands insulate heat from the surrounding ones causing it to be too localized? This was 5/16 cable and I really expected to to burn a nice weld on the two diameters forming the loop. I"m sure some type of braze alloy would work, but the mig was most availible for me. Could it have been more the nasty plating on the strands causing the problems. I finally just used cable clamps and welded the nuts solid. Clunky looking, but it will suffice.

I"m in the process of building a locking cable securing system for jobsite equipment. Any suggestions on welding wire rope to mild steel plate? I didn"t know it there is anything special about rope as far as composition a/o weldability that I should know about. I have about 200ft of 5/8 cable that a friend gave me after re-stringing an over head crane. That"s all I know about it. It"s been in my arsenal of "get the tractor unstuck" gear for a while. I figured I would cut a few lengths off of it to use for this project.

Welding two ropes together is common in the steel industry. If properly done, welding may develop sufficient strength to complete the rope installation. However, the welded portion of the rope is rather stiff, and the welded steel wire material may become brittle. Since the welded portion has to pass over sheaves, there is the danger that the weld may break.

If installing Python® wire rope as well as all non-rotating types we do not recommend the welding procedure. Welding might damage the seizings and the rope may unravel getting damaged beyond repair.

A common method for heavy crane rope installations. A steel sleeve only slightly larger than the rope diameter is swaged on to the rope end and a small auxiliary cable protrudes from the sleeve. Either, the old rope is furnished also with a becket loop, or the old rope will be connected to the becket loop with a cable grip.

Non-rotating rope must be installed with a swivel between old and new ropes. The old rope may have developed torque during it’s working life and we must ensure that this torque is not transferred to the new rope.

Python® types Multi and Super 8 may be installed with a swivel. In fact, if you have to change either of these constructions for a 6-strand rope, particularly when this rope has a different lay direction, a swivel is of definite benefit.

Python® Power 9 and Python® Ultra must not be installed with a swivel. Doing so will unlay the rope and damage it beyond repair. Use two cable grips and connect them with an auxiliary cable.

When using cable grips, the end of the grips have to be tightly seized on to the rope body to prevent accidental slip-out of the rope. Alternately, you may wrap the grip end with a strong reinforced industrial strength adhesive tape.

PA welding machines command attention with their efficient design and construction. The manual clamping device with optimized ergonomics is the basis for this robust but also inexpensive version.

In SE as well as PA welding machines, the wire rope or cable ends are inserted into a tube made of ceramic or graphite until the ends touch. Ceramic is the material of first choice here. As a rule, we use graphite tubes from > 400 mm² (version G).

After starting the welding process, the two ends are welded together by the current which then flows and the upset force which is applied. Optionally, preheating is carried out to achieve an optimal temperature profile. After completion of the weld, the tube is broken off. The surface at the weld is burr-free, clean, smooth and only imperceptibly thicker.

Operation of STRECKER welding machines is easy to learn. The pneumatic welding clamping fixture is standard equipment starting with the SE12 and meets the highest demands in terms of convenience and ergonomics (the same applies for the PA100-SE). The upset pressure is then also pneumatic. The compact and robust machine design with intuitive operator guidance is designed for industrial use in production.

MS and MK welding machines are designed for larger cross-sections, the highest quality and documented reproducibility with wire ropes and cables of up to 2500 mm² made of aluminium or copper. We meet the highest requirements for the smallest possible single-wire setups, class 2 to class 6 applications, as well as for high-strength alloys. Even wire ropes with different diameters can be welded with a minimized heat-affected zone. The burr is removed in the welding clamping fixture and caught in the machine. The result is a homogeneous, very thin and pore- and burr-free connection. The MS and MK series are equipped with our innovative FullParameterControl (FPC) control system as standard. The complete welding recipe is stored safely and with accurate repeatability in the controller. All settings of the machine are made automatically according to the recipe selected with no operator intervention. As an option, the quality of the welding process can be monitored with the STRECKER parameter monitoring system.

A 3-phase direct current transformer is employed to counteract the high current consumption or short-term peak load that occurs when welding very large conductor cable cross-sections. This reduces the current consumption.

Bekaert offers a wide range of coated round and Z-shaped steel wires for the production of hauling and carrier ropes. The wires that make up the rope core are of consistent quality. They feature high tensile strength and excellent ductility, leading to optimal fatigue resistance and a high breaking load. Moreover the round and Z-shaped wires can be coated with advanced coatings ( Bezinal®, Bezinal®3000 ). The combination of these features provides the right requirements for any traction or track rope: safety, stability, sustainability and less maintenance.

Because cable way projects mean a significant investment, we help you manage costs with economical and streamlined production. Bekaert offers Just-In-Time delivery that keeps up with the planning of your projects. Our cable way rope wire is produced according to EN-10264-2 or EN-10264-3 specifications. You can also set specific mechanical requirements to customize your rope.

316LSI Welding Wire is used for TIG, MIG and SAW welding. It shares similar characteristics as GEN 316L. The high silicon content allows better arc stability along with smoother bead appearance while the low carbon content offers excellent corrosion resistance against carbide precipitation. Higher productivity could be realized in the MIG welding process.

All welding products are supplied with a certificate of conformance stating physical and mechanical properties including alloy chemistry. Every welding product is manufactured to have its own unique lot identification number for full lot traceability.

Multiple packaging and shipping options are available from our facilities in the US, Canada, and the UK. Learn more about our products, the industries and applications we support, and how CWI Generation4™ welding wire can work for you.

While you’re looking at welding wire, here are Three Reasons To Source Your Welding Wire and Demister Pads Together. By ordering all your turnaround supplies from CWI, you can reduce downtime, perform maintenance all at once, and work confidently knowing you are receiving only the highest quality products from a trusted manufacturer.

Back to the joining challenge: Ultrasonically welding cables with significantly larger diameters logically requires the use of much higher power, along with the ability to hold the parts firmly in place while delivering it. For conductor diameters larger than about 60 square millimeters, there can be a point of diminishing returns with typical ultrasonic metal welding technology. The higher power levels needed to bond larger conductors may stretch or exceed the capabilities of current ultrasonic welders, since the typical cantilevered actuators used to apply clamp force tend to give and thus lose a robust grip on the parts. To compensate, amplitudes are often increased, which tends to exacerbate the problem. The results are an increase in weld-related stress, damage to the conductors, and failure to provide a reliable, high-quality weld.

Finally, the reliability and effectiveness of weld tooling are diminished, since higher amplitudes and power cause the weld tooling that should normally compress, grip and rub the cable strands against each other to lose grip and begin sliding against the cable strands. Such tool slippage results in rapid and excessive tool wear, increased tool replacement and refurbishing costs, undue stress on welding equipment, and increased energy consumption.

One logical remedy for tool slippage caused by higher amplitude and power would be to greatly increase the clamping force used in the weld process. However, testing demonstrated that when welding cable diameters larger than 60 square millimeters, the cantilevered press actuators used in many current ultrasonic metal welders are pressed beyond their mechanical limits.

The optimal solution eliminates the cantilevered press actuator in favor of direct downward force on the parts to be welded. Direct downward force delivers a robust hold on the parts throughout the power and amplitude range to maintain control over the weld process. This solution, developed by Emerson, is found in a new generation of Branson “direct press” ultrasonic welding equipment, typified by the Branson GMX-20-DP welder. This equipment delivers on two essential capabilities. First, this re-engineered equipment is capable of exerting high levels of clamp force on large cables—up to 6,100 newtons. Second, it can efficiently manage delivery of the significantly higher power levels needed to generate the vibratory motion and frictional heat essential to welding large conductors together under higher levels of clamp pressure.

At the same time, Emerson set to work on improved tooling that would overcome the problem of rapid tool wear under the stress of higher clamping forces. This new tooling—applicable to both horn and anvil—combines new coatings that increase tool hardness and durability with special knurling that gives weld tools an increased grip on the cabling. When this improved tooling is combined with the capabilities of the new “direct press” ultrasonic metal welders, the result is a markedly more efficient and repeatable large-cable welding process than cantilevered press welders can provide.