Quote Originally Posted by Rambozo View Post
onlinemetals.com has small lengths of 4140 and 8620 for good prices.

Weldmetal machining is always a crap shoot as far as hardness if the part isn't annealed after welding. So much depends on how much heat went in, for how long and how it was cooled. I wouldn't even think about machining weldmetal without carbide or ceramic tooling. Cobalt just doesn't cut it. FWIW I have often clamped a die grinder to the compound to use as a poor man's toolpost grinder.

You could TIG it up with 4130 rod. That would require a preheat, weld, anneal, machine, then heat treat. Seems like a lot of work over just using the right material. Time is money, too.
Ok, that may work... looks like 4140 would put me out around $50, factor in the time savings and it'd be about even. Still a hell of a lot cheaper than the tool steel I originally priced. I do have some good quality carbide inserts, it'll be a bit tricky for some spots, I was hoping to use cobalt with a profile ground to make it a bit easier on some of the complex curves. I eliminated the punch aspect, so that makes it easier, rather I'll drill as a pilot for the dies.

Been lucky so far, haven't had an issue turning weld metal. Good setup, nice sharp tooling, proper feed and speed, etc.

A small aspect of this was the facing, I'm trying to get myself dialed back in on all the processes. Knocked out some mitered AL this weekend, bear of an extrusion, 1/16 sections leading into 1/16 webs, another gap, then a 3/8 thick section mating to 1/16... Wish I took pictures. Was quite satisfied with the end result and the shop owner, whose display case door it was is ecstatic. I'm nice and happy on steel again and fresh Al, cast is going to take some more playing. I think I got the 6011 figured out, you were right, way different with an inverter. Amazing how much I retained over 14 years, also amazing how much I forgot

This also applies to some other odd shaped pieces that may come up, I'll have to evaluate those on a one on one basis as to what alloy and process.