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[Patrick Wang]

I am a apt TIG welder myself, I have mostly had my experience welding aluminum frames together.

Knowing that the heat from the welder is going to bend the shaft if you keep the heat on too long, does anyone have advise as to the proper way of welding a gear to a shaft and how much weldment you actually need.

Two years ago, we tried to build a ball grabbing device with welded sprokets onto drill rod. (This is probably a bad basis for judgement because the design was flawed from the start had, 16 in of unsupported rod) but we had the drill rod shear. Now, I don't believe that a shear would be because of the weakening from the weld, if anything I'd think it was bend out if the drill rod was warped from heat.

Basically what I am looking for is someone to tell me that there is a way to weld a gear/sproket to a shaft without damaging the shaft. And how great are the benifits? (it seems that the little weldment just intuitively would offer a lesser degree of maximum torque than a key or pin)

Thanks again for all the replies