A Silly Question(s)

Joe The Armor Weenie · Mon Apr 30, 2001 12:56 pm

Hello I have a small question that is probably very broad in possible answer. So without further adieu the can is open and the worms are everywhere.

I am looking for the easiest, and cheapest method for creating welded chainmail. I have heard that the Mig or Tig welders would work wonderfully for this application. I was told that basically you pull de trigger and *zap* a weld or hold it down and you get a long *zap* this sounds ideal but I don't know if my well meaning friend is blowing sunshine up my kilt or not. I am hoping to be welding galvanized, stainless, and if possible aluminum in the future if things work out. Well, there it is and the worms be wigglin.

Can anyone help me out?
- Joe

p.s. I'm blissfully ignorant until proven otherwise

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Proverb- If at first you don't succeed, don't try skydiving.

schreiber · Post by **schreiber** » Mon Apr 30, 2001 1:07 pm

Welding galvanized is a hotly debated topic. From what I've read, it's not good to be exposed to vaprous zinc. Apparently it leaves your system after a short period of time (a day or so), but it's not good to inhale it. Flu like symptoms, I think.

Aluminum oxidizes the instant it's exposed to oxygen. The only way I'm aware of for welding it is with a heliarc welder. Not cheap.

Don't know anything about migs and tigs. I can tell you that you may be on the wrong track.

I don't have anything to back this up, but I was given the impression that welded maille was actually braised or soldered, which would be a lot easier.

I am also looking to make aluminum maille in the near future: I am going to try to find solid punched rings for half of them and butt the rest. If any future readers could enlighten the both of us as to where we can find said hardware (I'm going to need 10k+ and don't want to spend more than about 150 for them) I'm sure we'd both appreciate it.

HELMUT

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Bridging the gap between his contemporaries, Helmut wore boxer- briefs.

Mad Matt · Post by **Mad Matt** » Mon Apr 30, 2001 1:09 pm

Pre-overlapped rings and a spot welder.

Pre-overlapped rings come from a spring manufacturer. Just make a professional sounding inquiry.

Solid rings come from a washer manufacturer.

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The budding mid 14th century German Transitional guy.
Mad Matt's Armory

Clay · Post by **Clay** » Mon Apr 30, 2001 1:29 pm

Welding galvanized is something you should do if you've already tried slitting your wrists or hanging yourself and haven't gotten the desired results.

Seriously, welding galvanized sheet/wire is just nasty. It cracks, burns, pops, and smells like crap. It just looks ugly. Plus, all that crap (that's the technical term for it BTW) gets into your lungs. I don't know about you, but I only like fresh air in my lungs!

If you're going to weld maille, I would suggest stainless steel or mild steel for the rings.

Sorry I can't help with your question, but I thought I'd throw my two cents in since galvanized maille was mentioned.

losthelm · Post by **losthelm** » Mon Apr 30, 2001 3:27 pm

you can weld aluminum with a tig or a mig welder but you have to use the aluminum wire\fillrods and a shielding gas

I think that the mix is about 25% argon and 75% helium at 20pounds
that is a ruff estamite on the mix of shielding gas your millage may vary
I only got to weld aluminum once it can be done but only with a shielding gas

check your welding manual first

Deacon · Post by **Deacon** » Mon Apr 30, 2001 3:58 pm

Here's everything I know about health risks from welding galvanized: http://www.brothersgrymme.org/arador/forum/archives/199907/messages/2599.html

Hope it helps,
Deacon

Brian · Post by **Brian** » Mon Apr 30, 2001 4:07 pm

I buy aluminum for mail from the local farm and home store -- Look in the electric fence wire section. I buy 14 ga. for ~$28 per 1/4 mile.

Hope this helps

Brian

Alcyoneus · Post by **Alcyoneus** » Mon Apr 30, 2001 4:10 pm

Maybe a specialized jewelry welder. Fusion?

Sasha · Post by **Sasha** » Mon Apr 30, 2001 6:33 pm

Firstly...A note to Helmut.

Helmut, I do not wish to offend, but I have now read a couple of your posts regarding welsing. May I ask what ,if any qualifications or experience you have in the field. You have some answers that are "original" about the properties of welders and metals.

Now on to the question. My advise would be to go with the tig. It will happily do aluminium USING ARGON AS ITS SHIELDING GAS. And will also do a nice and fast job on the other materials mentioned (providing you use the right filler rods).
Tig is a pretty easy for spot weld applications (what you want to do) once you have done a little practice, or preferably a short course in safety and procedure.

I cannot stress this enough, there is no substitute for a couple of days of supervised learning under a qualified instructor when it comes to any form of weldiing. Getting the experience to become a great welder will take no more then a lot of years of work and practce....but learning how best to set the valves and power-switches is a critical point form where to start.

The other option I would recommend (cheaper in start up costs but more costly in consumables) is to go wiith a small oxy-acetylene pack (size 6 tip or smaller) you can make welded links very quickly with this method (INCLUDING ALUMINIUM, IF YOU USE THE RIGHT FLUX).

Basically a half decent tig welder is pretty pricey, a good oxy is pretty cheap. The tig costs not much more then the price of argon gas to run (the odd tungsten tip and the very cheap filler rods), the oxy requires oxy and acetylene (plus the rods and the odd tin of flux)....actually...in the US there would probably not be that much of a difference in operating costs (Argon is expensive here)

Sasha

Raselsnarf · Post by **Raselsnarf** » Tue May 01, 2001 5:24 pm

Okay now on the galvanized steel debate I can only say this. I really don't like Galvanized steel. Granted it is cheap and easy to get. It is also great for people to use when just learning chain maille. However, it is smelly, it can change the skin funny colors, and it oxidizes easily. As far as heating it up, yes it does release a toxic fume that is harmful to the body. It may not be fatal but you know, I have enough problems with my body without adding to it. Well, good luck in your search for knowledge. This is my two cents worth.

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Kiernan Delaney
The Drunken Irishman