Well, I've done a lot of TIG welding before and I have never come across a more difficult welding job than this - not even trying to weld over GAL. It is the first time I have tried to weld 4130 chrome moly (if it actually is crome moly - I'm beginning to wonder).
I removed the rod ends, ground and polished all the CAD plating off, thoroughly sanded the inside and outside of the 4130 tube and cleaned everything with Acetone. Still, the 4130 tube wanted to leap onto the TIG electrode with monotonous regularity.
I finally made welds that appear to be OK (proper penetration and without mounds of metal), but little holes appeared regularly as metal popped away, so I may still yet have them X-rayed for integrity - I don't want these parts failing !!
