I forged out a bent handle chisel from O1 stock, but had cracks at the point where the handle met the chisel body, which I gas welded with ER70s rod. The cracking continued to be a problem, but I thought i had it whipped until I was trying to rivet the end of the tang on the handle, and the whole handle fell off. i want to save the work I did; any advice on welding on a tang? I have gas, stick, and TIG equipment available.

I would TIG weld it.

The big issue is keeping it from air hardening and cracking again.

 

So maybe TIG weld on a mild steel handle after preheat, stick it in the forge, then into some vermiculite for a slow cool, then reharden the chisel tip?

Or start over, which one will be less time and more prone to work?

I"m with Biggun, it'll be a lot less work and more likely to work starting over. 

Frosty The Lucky.

it's never too soon to start a good scrap pile. 

If I start over, the same thing could happen; plus all the labor i already put into it will be lost. or, I can see if my recent repair of my gas solenoid worked on the TIG unit, weld on a handle, and use the chisel to finish the shirasaya for the sword I am polishing......option B works for me. Scrap pile is pretty big already

1 hour ago, Steve Shimanek said:

finish the shirasaya

Without pictures it didn't happen. When it's finished please post it in the knives section.

I guess it happened....first time in a good while i had the TIG attached to the welder. Tacked it up, then preheated with a MAPP torch, and finished welding it, then put it in the vermiculite bucket to slow cool. I didn't need to reheat treat the working portion, since it didn't get hot enough to change the temper. It even withstood the accidental drop test.

18 hours ago, Steve Shimanek said:

If I start over, the same thing could happen;

Yes it could, welding it could fail too. Can't live you life by letting what might happen make your decisions. Sure you need to be aware of failure conditions and take them into account but not trying because it MIGHT fail is a sad thing.

Frosty The Lucky.

Sure is, that's why I put on my xxxxxxxxxxxxx and welded it instead of hammering out a new one......as a disabled vet I need to make all my efforts count.

It occurred to me some time after I couldn't edit my post the same thing goes for giving a shot at welding it up. It might not have worked but can't live dodging what might not work. Making it count is a better motto.

Thanks for serving Steve.

Frosty The Lucky.

Exactly Frosty, if I tried and failed in the repair i would have had to make a new one anyway. As  only the sacond chisel I have done, I have learned a few things by this evolution; O1 is hard stuff and doesn't yield easily. (Glenn has explained my social gaff as having failed to anticipate some theoretical parent's embarrassment in having to explain to a child what my phrase meant. I can live with learning new ways of social engagement.)

Thank you for acknowledging my service; I was not an Army Ranger, I only spent 11 days trying to be one The jump did me in.......

8 hours ago, Steve Shimanek said:

O1 is hard stuff and doesn't yield easily.

Very true. It also can hot short and crumble if overheated, so don't let frustration lead you to work it too hot.