How does this compare to the strength of DSFC

Have you considered a induction heating coil? JD Brewer had one in his latest podcast. If all your parts are smallish i would consider that route.

If the customer will go for it offer them a discount to develop the process? Maybe they can send you some test parts to braze/ silver solder. You can send them back for testing and approval.

Tell them your developing a new process to be more efficient, if thier willing to work with you it's mutually beneficial

I'm no CWI, but a series of overlapping spot welds with craters seems problematic. Lack of fusion, stess cracks all seem highly probable. But hey it's just a role cage, what could go wrong...........

Yes the bottom of the weld would be 4F I believe. I cleaned everything back to bright clean material.

Thank you

Thank you!

If I have a problem with the weld falling out, large balls of weld, would that generally indicate running too cold?

23v @ 240 in/min 45 cfh .045 Lincoln ultra core.

Kevin Fox thanks, I pulled off some decent welds.

I can't seem to get overhead figured out. It wants to fall out bad. Maybe hotter with more arc force?

That's more then I have seen without a contaminated tungsten.

Post flow, bad gas, air leak, contaminated tungsten

Any tips to diagnose worm hole porosity? I seem to always get it.

I am going to be using DS tommorow to build some frames. I always end up having problems with worm hole porosity. Can you give some tips to help diagnose when this happens? I'm going to try your suggested settings!