New billet,,, in the bottom of the forge :(

[springer82]

I got a 125 Hobart welder. I tried welding my billet to the end of a piece of rebar. That lasted for a few times into the little giant. Then it dropped to the bottom of the forge. :what!:$&*#!@@%,,, lol So,, did I put the billet to far into the forge or is the 125 not good enough to do the job? I'll be back to the tongs. Life is good!!! Thanks for your help.

 

[IanBryant]

I would guess that your welds got hot with everything else and let go....Maybe weld it a little hotter next time?...better penetration and whatnot. I don't know how big (heavy)the billet is but I would think your buzz box to be sufficient.

Disclaimer, I am neither a welder nor a blacksmith. I am a toolmaker that has dabbled in both.

 

[EdCaffreyMS]

It's the combination of dissimilar metals (especially the weld material and the steel in the billet), in combination with the heat, and shock from the hammer. It's common for stick or MIG welds to let go after a few heats, and a few times through the hammer.

To minimize the issue I use a larger diameter rebar for billet handles.... 5/8" or larger, and weld all the way around the handle/billet junction, then run a weld bead from each corner of the billet, to and slightly up the rebar. It's not 100% solution, but it has dramatically reduced handles "breaking off" during welding. If you see the weld starting to separate, STOP and reweld it.....that will save you from having to fish a billet out of the forge.