Butt welding ends of 1/16" stainless wire

Jan 06, 2011 6 Replies

The tab on my son's jacket zipper, that you would grab to move the zipper up and down, broke.



I made a replacement as an oblong ring made of 1/16" 316 stainless TIG wire. By the way, this can be done super nicely and easily using round nose pliers -- the result is great looking and is easy to make.



Anyway, in the end I had to weld the link shut, as a butt weld. I used the same wire as filler.



It worked, but left a little "bulb" near the weld. After careful grinding, it is fine, but I wonder: Is there some secret technique to such welding, that would make the weld look very similar to surrounding wire? (TIG)



i

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Though it's difficult with TIG, stretching the joint as it solidifies can remove most of the bulge.

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bought a tapered pry bar, annealed it, turned the taper longer and rehardened it. For cruder work I use cheap tapered pin punches as anvils to forge small rings and flares. Stainless forges pretty well cold without cracking, though it can dent the anvil.

jsw

=A0 =A0 =A0 Dan

That's what I used to do.

That's what I used to do.

Reply: I still get a small blob on the junction.

That's what needle files are for.

jsw

glegroups.com...

=A0 =A0 =A0 Dan

I used borax flux, a tiny piece of silver soldier and used a Prestolite torch. Karl

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