If the wall thickness is .020" and it is subjected to 1000 psi internal barrel pressure, it will have a hoop stress of approximately 18,000 psi. Since 1035 has a yield strength of ~40-50k psi, this is over 2:1 safety factor. So, welding it with a mild steel rod and striking it down to .020" should be more than adequate. Although a matching alloy could be used, my experience is that a lower carbon steel rod helps prevent a concentration of excess carbon and cracking along the edge of the weld. I have made copper plugs that fit the bore well, then TIG welded barrels successfully.
I recall Dr Oscar Gaddy shared with me that he had successfully TIG welded a damascus barrel at one time.
From what I see there in the picture, I would investigate further to determine if those are small cracks running radially. If so, I'd weld those, possibly in a radial weld bead.
Last edited by Chuck H; 09/22/25 11:36 AM.
