For this particular project a friend of mine is trying to get a shaft into a hub. It's a home project so you can throw the code book out of the window. We're too the point of just needing it completed with limited resources. It's an A36 hub to 1045 shaft. I've read the past questions on this and still have my own questions. At first it was supposed to be 1018 shaft, So we preheated about 225 and welded with our .045 flux cored 70 series, 100%CO2. After cooling we noticed some cracks along the entire pass. Some in the center, some at the toes. We called the machine shop and he said he didn't have any of the 1018 so he done them out of 1045. With this new knowledge I done what I thought was right. We used the same process except we heated to 600 degrees and then used some welding blankets to slowly cool it. Still cracking just not as bad. In the morning we're going to get some freshly sealed 7018 and repeat with the same heating and cooling techniques.

My question is if we can make this work with what we have on hand. We have some .035 solid wire. The only problem is we do not have any 95/5 gas to run a spray transfer. We do have a bottle of 100% helium, and 100% argon. Would either of these achieve spray transfer?

Does anyone notice something obvious I'm missing that I could be doing differently to solve the problem? Thanks