Welding & Metallurgy: Possessed Steel & Luder Lines

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The discussion centers around the challenges faced by a restoration welder at the Seashore Trolley Museum in Kennebunkport, Maine, particularly when working with vintage steel from trolleys dating back to the early 20th century. The welder is experiencing difficulties when cutting across a Luder line and attempting to weld new steel to old, specifically noting issues with warping and unpredictable welding behavior in certain areas, especially near the doors. The use of Pulse TIG welding and stainless electrodes to manage impurities in high carbon steel is highlighted, along with the complications of differential expansion. The welder ultimately had to replace an entire sheet due to persistent warping, indicating the complexity of working with aged materials. The conversation invites insights and solutions from others in the welding community, suggesting additional forums for further discussion.
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I have to ask this...I work at the seashore trolley museum in kennebunkport Maine as a restoration welder/fabricator. I work with old trolleys and old steel from 1907 to the 1950's and they all tell a story. I don't know how to put this to words but let me give it a try. What happens when you cut across a Luder line, and then try and weld through it? I am replacing the bottom half of a 16 gauge sheet metal panel and joining the old steel to the new takes quite a bit of black magic and welding witchcraft. Since not all things are created equal, sometimes the welding goes smooth and then there are pockets of trouble, but then there are times when there is an area that just goes out of control and no matter what I do the area just won't play. In this particular case the steel by the doors just seems to be possessed. Could it be that I am welding through a luder line? I ended up having to replace the entire sheet after trying to heat shrink it...to the point that I ended up tearing the sheet. It just continued to warp in the same spot. I am using the Pulse TIG process. At times I have to use stainless electrodes to trap impurities in the old high carbon steel and I try to compensate for differential expansion etc. Let me know what you think on this and thanks for your input. I seem to find these spots when welding and it can make a good day go horribly wrong!
 
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