Wow! Thats cool. I dig the unique application. I have a better idea of what your facing now that the picture is shown. Very cool.
I have to tell you, I have a folder that my screen saver goes to, those pictures are in it. When I was instructing, I would have saved them for inclusion in a power point presentation. Those guys are lurking and thanks on their behalf for sharing.
I attached a picture to my previous post, I think I did? I did a demo on the fly of the similarities of the GMAW process to SAW. I do have a video, to big to post. But with the gas shut off, nozzle removed, gun taped in position to a radiograph, I guessed on parimeters. I used a empty ice tea bottle and poured the flux. Stick out was around 1 1/4" with wire cast ruling that factor in the .035 wire. Wire helix gave it a slight stir as it progressed. While shy on penetration, some what underfilled, she was ductile and bent in one piece go figure? Got lucky that day.
I did the same demo with straight sand if your curious of the results?
I might mention, I knew an old welder years ago who made his own Sub Arc to rebuild/build up worn equipment brake drums in his garage. You gave me a warm fuzzy feeling with your pictures.
I told my students at the time, if they played the game right, they could weld vessels in there garage. They looked at me like I was nuts. Maybe so? But I don't think so.
And I like your wish list lol. Thats quite the arm. Technology has come along way baby. In this day and age, the thinker gets the gold ring. While you don't mention where in the shop food chain you sit, I like the way your thinking! While my age has me a bit skeptic when it comes to tech advancements, the advancements benefit all. The real time monitoring during welding operations if viewed with a trained eye is a score to avoiding rework challenges.
Now, if they mount them in a welding helmet to track eye movements...we can solve another great mystery.
Thanks again Steve.
Noel