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Fabriaction of fan with blades made from Corten A, 6mm thick vanes, 1600mm dia, welded to mild steel hub 30mm thick with 400mm bore. Using Corten to not have to paint and would also not want to stress relieve either. Completed an ANSYS study showing at over speed welds are below fatique limits...

Problem: Alternator Rotor winding failure (Turn to turn.) only on 400volt machines in parallel with grid. Not on high voltage machines on same installation. (Rotor construction identical.) Site conditions: Very weak grid, with lots of loss of mains. Lots of power factor correction...

Assuming it is ASTM A353. Can be used for very low temperature service. AWS specification is A5.11-76 or A5.4-78. Electrodes can be ENiCrFe-2 (95% joint efficiency) or ENiCrMo-3 or E310. These are suggested electrodes for shielded metal arc welding of high strength low-alloy steels for pressure...

The 3rd harmonic is generated by the pitch of the machine. 2/3 pitch eliminates it. However you have the correct pitch for grid connection. Neutral earthing is the cure. You need a fault limiting reactor or resistor on the neutal to earth to limit the third harmonic.

From the alternator industry. This rule of thumb can be applied generally. The difference in output of a machine from Class B rating to F as an example is the square root of the temperatures. i.e. 105/80= 1.31. Square root = 1.14. 14% increase in output. However remember that often generators...

The sub-sea oil industry have to do similar things. There may be some technology there. From previous experience they have had to do this type of process.

No I have no such experience, but why can't you use a flanged joint. Torquing up a 50" thread would be a nightmare, without very special tooling, quite apart from gauging the male and female threads.

I don't know the thermal capacity of what you are welding, but there are commercially available, compressed air driven cooling pipes, which eject hot air from one end and cold air from the other. They could be used for small components to cool.