Author - BCC Group

The first big-size-plate machine

Recently, BCC Group has installed the first machine for our wear plate production business. with this new investment, we now can produce the plate up to 3000mm width and 6000mm length. By the end of this year, we plan to add 03 stations more so that we can fit our customer demands in Australia, Indochina countries, UEA and South Africa.

Here is detailed information of our system:

  • Number of welding heads: 04
  • Capacity: 02 sheets of 3000x6000m
  • Thickness: maxium can be 50mm

Some photo and videos:

wear plate production

machine working principle

System during installation

System during installation

System – Reading for welding

System – with power source – Lincoln DC 1000


 

CORROSION RESISTANT COATING

The selection of corrosion resistant coating materials is more complicated. The working condition, working temperature, working environment and various kinds of corrosion media have all increased the requirement of coating materials. Corrosive environment may be aqueous solution, gas or a variety of chemical media, but also may have a wide range of temperature. In the presence of gas conditions, the burning of gas or non-burning fuel may also be at the appropriate temperature and other substances react, forming a very complex corrosion environment.


Resistance to atmospheric corrosion

Such coatings are resistant to the following conditions: metals or alloys are exposed to the atmosphere in the outdoor or indoor atmosphere, which can resist the corrosion of wind, rain, sunlight and other climate change conditions in the atmosphere. The coating used in the outdoors can also be used well in the interior. This kind of coating includes the coating of industrial atmosphere, the corrosion resistance of the coating and the corrosion resistance of the atmosphere in the countryside.

1 Coating for industrial atmospheric corrosion

Resistance to industrial atmospheric corrosion coatings can withstand the harsh atmosphere of soot or chemical smoke (such as large cities and heavy industrial areas, etc.), can be sprayed Zn, Al coating. This type of coating must be sealed, the choice of sealing agent is very important, the specific selection and construction considerations can be referred to in the sixth chapter arc spraying.
This type of coating is commonly used in all types of structures and components of steel, electrical conduit, bridges, transmission lines, metal components, lawn and garden facilities, etc.

2 corrosion resistant coating for marine atmosphere

The coating can withstand corrosion in the vicinity of the ocean or under salt spraying conditions. Commonly used in the bridge above the waterline, dock structure above the waterline, storage container, ship’s superstructure, the surface of the transformer etc.

3 Resistance to the coating of atmospheric corrosion in the countryside.

The rural atmosphere, although there is no industrial smoke and marine climate of salt fog, but contains a little of the pollutants. They are usually mild and dry.
Corrosion resistant coating
Immersion corrosion is metal or its coating is exposed to the liquid, and is all or part, or two alternately by dipping, anti-corrosion coating must be able to withstand the above or below the level of the liquid surface environment. This kind of coating is as follows: resistant coating, non-edible fresh drinking water, fresh water, heat resistant coating corrosion coating, chemical and food industry using the coating.

3.1 drinking water resistant coating

The coating is resistant to fresh water, and cannot change the chemical composition of the water. In order to meet drinking water requirements, cannot use the chromate containing sealant. Spraying Zn coating. Commonly used in freshwater reservoir; aqueduct (aqueduct, aqueduct, aqueduct), filter tank, water delivery pipe.

3.2 fresh water resistant coating

This coating resistant to drinking water, the water temperature does not exceed 52 degree C, the pH value is 5 ~ 10. Spraying Al, Zn coating. Commonly used in power plant is introduced, the structure line device, immersed in freshwater sailing in freshwater hull etc.

3.3 heat resistant fresh water coating

 

The water is not drinking water, the water temperature is 52 to 204 degrees C, pH value of 5 ~ 10, can be sprayed Al coating, but to seal the hole. Used for heat exchangers, hot water storage containers, steam cleaning equipment, and parts exposed to steam.

4 salt resistant coating

The coating can be completely or partially immersed in a stationary or moving salt water or seawater. The structure of the static state, the scope of the sea water immersion should be extended to the mud line under the 0.914 meters above the tide line; the higher the range, should be considered as “Salt atmosphere”. Spraying Al coating. Commonly used in marine engine oil pan, steel River pier, pile and hull, rudder and fish in the fish tank, the hull below the waterline are dirt problem areas etc..

5 coating for chemical and food industry.

The effect of chemical coating to resist such as oil, fuel and solvent, and corrosion resistant to various food, but cannot change the chemical composition and taste of food, can be sprayed Al coating, but to seal the hole. Commonly used in gasoline, crude oil, fuel oil and xylene, ethanol, butanol, isoamyl acetate and toluene and other chemicals storage, brewery mash tank, soft drinks and dairy equipment, dairy equipment, food oil tank and molasses tank, glycerin groove lining, sawdust washing machine etc.

CORROSION RESISTANT COATING

The coating can withstand the corrosion of various acids, bases, salts, solutions, steam, and solids. This type of coating is mainly iron-based, nickel and cobalt alloys, self-fluxing alloy, nonferrous metal, ceramic oxide, chromium carbide and tungsten carbide metal ceramic. As the thermal spray coating has a certain porosity, so, all kinds of coating must be filled and sealed. The sealant itself must be resistant to chemical corrosion medium.

In order to resist chemical corrosion, all coatings used in a given environment, must use the recommended sealant for processing. The use of specialized sealants, will not damage the coating mechanical properties. However, under high temperature coating corrosion resistant ability depends in part on sealant.

Hardfacing definitions and Frequently asked questions

At first glance, hardfacing can be confusing and troublesome; in reality, it isn’t. Understanding some of the basics about hardfacing can go a long way toward instilling confidence in your hardfacing product selection.

The following 19 answers to frequently asked questions may help you select hardfacing products that are most appropriate for your application.

1. What is hardfacing?

Metal parts often fail their intended use not because they fracture, but because they wear, which causes them to lose dimension and functionality. Hardfacing, also known as hardsurfacing, is the application of buildup or wear-resistant weld metals to a part’s surface by means of welding or joining.

2. What base metals can be hardfaced?

Carbon and low-alloy steels with carbon contents of less than 1 percent can be hardfaced. High-carbon alloys may require a special buffer layer.

The following base metals can be hardfaced:

  • Stainless steels
  • Manganese steels
  • Cast irons and steels
  • Nickel-base alloys
  • Copper-base alloys

3. What is the most popular procedure used to apply hardfacing?

In order of popularity, the following procedures can be used:

  • Flux cored arc welding (FCAW)
  • Gas metal arc welding (GMAW)
  • Shielded metal arc welding (SMAW)
  • Submerged arc welding (SAW)
  • Gas tungsten arc welding (GTAW)
  • Oxyfuel welding (OFW) or oxyacetylene welding
  • Plasma transferred arc welding, laser welding, thermal spray, and brazing

FCAW and GMAW may be interchangeable or the same in terms of popularity. However, the trend is toward use of semiautomatic and automatic welding procedures.

4. With so many welding processes available, which ones are the most economical?

Many factors affect the economics of hardfacing, but a major one is the deposition rate. Figure 1 shows the estimated deposition rate fo

 

r each process.

5. Wear is such an all-encompassing term. Can it be broken down into more manageable categories?

Yes. Many different categories of wear exist—too many to cover in one article—but the most typical modes of wear are as follows (percentages are estimates of total wear):

  • Abrasion—40 percent
  • Impact—25 percent
  • Metallic (metal to metal)—10 percent
  • Heat—5 percent
  • Corrosion—5 percent
  • Other—5 percent

Most worn parts don’t fail from a single mode of wear, such as impact, but from a combination of modes, such as abrasion and impact. For example, a mining bucket tooth usually is subjected to abrasion and impact, and depending on what type of material is mined (soft or hard rock), one mode may be more dominant than another. This will dictate the welding product used.

Determining the wear mode can be challenging and may require trial and error when you select hardfacing products.

6. Is there a convenient way to categorize the many alloys when determining which hardfacing to use?

Yes. Iron-base alloys can be divided into three main categories:

  • Martensitic. This includes all hardenable steels with Rockwell hardness from 20 to 65. This group, similar to tool steel, hardens upon cooling. They are good for metal-to-metal and abrasive wear. They also can withstand a great deal of impact.
  • Austenitic. Austenitic alloys include work-hardening steels, such as manganese and stainless. This group generally is soft when it’s welded and hardens only after the weld metal is worked. They have good impact properties and moderate abrasion resistance. The stainless steel family is good for corrosion resistance.
  • Metal carbide. These alloys contain large amounts of metal carbides in a soft, tough matrix and are good for severe-abrasion applications. The alloys that contain large amounts of chromium and carbon are known as the chromium carbide family and are closer to a cast iron or white iron. Their hardnesses are from 40 HRC to 65 HRC. Alloys that contain large amounts of tungsten and carbon belong to the tungsten carbide family. Some contain small amounts of chromium and boron that form borides and are good for severe-abrasion applications.

7. Many hardfacing alloys crack. Is this normal?

It depends on the hardfacing alloy. Many chromium carbide alloys check-crack when cooled to moderate temperatures; this is normal. Others, such as the austenitic and martensitic families, don’t crack when applied with proper welding procedures.

8. What is check-cracking?

Check-cracking, or checking as it’s sometimes called, occurs in the metal carbide families and can be seen as cracks that are perpendicular to the bead length (see Figure 2). They generally occur from 3/8 to 2 inches apart and are the result of high stresses induced by the contraction of weld metal as it cools.

The cracks propagate through the thickness of the weld bead and stop at the parent metal, as long as it’s not brittle. In cases in which the parent metal is hard or brittle, you should select a buffer layer of a softer, tougher weld metal. The austenitic family is a good choice for a buffer deposit.

hardfacing surface

Figure 2

9. What is chromium carbide hardfacing?

Generally, these are iron-base alloys that contain high amounts of chromium (greater than 18 percent) and carbon (greater than 3 percent). These elements form hard carbides (chromium carbides) that resist abrasion. The deposits frequently check-crack about every 1/2 in., which helps relieve stress from welding. Their low friction coefficient also makes them desirable in applications that require material with good slip.

Generally speaking, the abrasion resistance increases as the amount of carbon and chromium increases, although carbon has the most influence. Hardness values range from 40 HRC to 65 HRC. They also can contain other elements that can form other carbides or borides that help increase wear resistance in high-temperature applications. These alloys are limited to two or three layers.

10. What are complex carbides?

Complex carbides generally are associated with the chromium carbide deposits that have additions of columbium, molybdenum, tungsten, or vanadium. The addition of these elements and carbon form their own carbides and/or combine with the present chromium carbides to increase the alloy’s overall abrasion resistance. They can have all of these elements or just one or two. They are used for severe-abrasion or high-heat applications.

11. Can hardness values be used to predict abrasion resistance?

No, this isn’t a good idea. A martensitic alloy and a chromium carbide alloy can have the same hardness, let’s say 58 HRC, and perform vastly different under the same abrasive conditions. The metallurgical microstructure is a better measuring stick, but that isn’t always available.

The only time hardness can be used to predict wear is when the alloys being evaluated are within the same family. For example, in the martensitic family, a 55 HRC alloy will have better abrasion resistance than a 35 HRC alloy. This may or may not be the case in either the austenitic or metal carbide families. Again, you have to consider the microstructure. You should consult with the manufacturer for recommendations.

12. If hardness is unreliable, then how is wear measured?

It depends on the type of wear involved, but in the case of abrasive wear—by far the most predominant wear mechanism—the ASTM Intl. G65 Dry Sand Rubber Wheel Test is used extensively. This essentially is a test in which the sample is weighed before and after the test, and the result usually is expressed in grams of weight loss or volume loss.

A sample is held against a spinning rubber wheel with a known force for a number of revolutions. A specific type of sand, which is sized carefully, is trickled down between the sample and rubber wheel. This simulates pure abrasion, and the numbers are used as guidelines in material selection (see Figure 3).

ASTM G65 Test Apparatus

Figure 3 – ASTM G65 Test Apparatus

13. What type of gas is used in GMAW hardfacing?

Low penetration and dilution are the major objectives in hardfacing, so pure argon and mixtures of argon with oxygen or carbon dioxide generally will produce the desired result. You also can use pure carbon dioxide, but you’ll get more spatter than you would with an argon mixture.

14. What is a ball, or globular, transfer, and why is it important?

Welding wires produce either a spray transfer or a globular (ball) transfer of molten metal across the welding arc. Spray transfer is a dispersion of fine molten metal drops and can be characterized as a smooth-sounding transfer. These wires are desirable in joining applications in which you require good penetration.

Ball transfer wires disperse larger molten metal drops, or balls. This type of transfer promotes low penetration and dilution, suitable for hardfacing. It has a noisier arc that produces an audible crackling sound and generally has a higher spatter level than spray transfer wires. Welding parameters such as electrical stickout, gas (if any), amperage, and voltage can affect the size of the ball and its transfer. Gasless, or open arc, wires all have a globular or ball transfer.

15. Must parts be preheated before hardfacing?

As a rule, you should bring all parts at least to room temperature. You can select higher preheat and interpass temperatures based on the base metal chemistry and hardfacing product you’re using.

Manganese and some stainless steels and similar hardfacing products require no preheating, and welding temperatures should be kept as low as possible. Other steels usually require proper preheat and interpass temperatures. You should consult the manufacturer for the best combination to prevent cracking and spalling.

16. When is a cobalt or nickel hardfacing alloy used?

Cobalt alloys contain many types of carbides and are good for severe abrasion at high temperatures. They also have good corrosion resistance for some applications. Deposit hardness ranges from 25 HRC to 55 HRC. Work-hardening alloys also are available.
Nickel-base alloys can contain chromium borides that resist abrasion. They can be good particularly in corrosive atmospheres and high temperatures when abrasion is a problem.

17. Why are some hardfacing products limited to two or three layers?

Limited-layer products usually are in the metal carbide families, such as chromium carbide and tungsten carbide. You can apply martensitic and austenitic products in unlimited layers unless the manufacturer specifies otherwise.

The brittle nature of the metal carbides leads to check-cracking, and as multiple layers are applied, stress continues to build, concentrating at the root of the check cracks, until separation or spalling occurs between the parent metal or buffer and the hardfacing deposit.

18. What is meant by a buildup or buffer alloy?

These alloys often resemble the parent metal alloy and are applied to severely worn parts to bring them back to dimension or act as a buffer for subsequent layers of a more wear-resistant hardfacing deposit. If the hardfacing produces check cracks, then it’s wise to use a tough manganese product as the buffer to blunt and stop the check cracks from penetrating into the base metal.

19. Can cast iron be hardfaced?

Yes, but you must take preheat and interpass temperatures into account. Nickel and nickel-iron products usually are suitable for rebuilding cast iron. These products aren’t affected by the carbon content of the parent metal and remain ductile. Multiple layers are possible. If further wear protection is required, metal carbide products can work well on top of the nickel or nickel-iron buildup.

These frequently asked questions only begin to address hardfacing. Hardfacing product manufacturers and specialists can contribute to a greater in-depth understanding of hardfacing and help assist you in product and process selection for your application

 

Source: thefabricator.com

BCM – The Automatic Welding Systems for Hardfacing / Cladding applications

BCC has been working and developing many products for hardfacing & cladding application since last ten years. Recently, we just launched new development of machine called BCM V2.

Download Brochure

 

  • BCM-V2 is a full automatic welding system – generation 2 which desgined and manufactured by BCC
  • BCM-V2 is a customized design for hardfacing / cladding works. It also can be applied for wear plate production.
  • The control panel of BCM-V2 is assembled from high quality components from Japanese Manufacturers. By this way, BCM-V2 can operate continuously at high productivity, difficult conditions like welding and high temperature.
  • With simple design of UI, BCM-V2 is easy for installation, operation and maintenance

Applicable ways

Hardcored™ Services: Hardfacing of VRM Grinding Rollers and Tables

With Hardcored™ Welding Technology, BCC provides a complete range of solutions for hard overlay welding. The following services are offered for vertical roller mills:

Hard overlay welded grinding rolls and grinding tables
Welding consumables of alloys specifically matched for use in vertical roller mills
Portable welding system consisting of welding head, control unit and DC power supply which designed and manufactured by BCC
Hardcored™ Welding service can be done either at the Hardcored Services Workshop or at the mill plant site

Hardcored™ Welding Services Offer the following Benefits:

  • New grinding rolls and grinding plates made of hard casting with and without hardfacing to ensure long service life-time
  • Regeneration of grinding rolls and grinding plates to avoid the purchase of costly spare parts
  • Complete, cost effective services Supply of hard casting and hard overlay welding from a single source
  • Excellent references in the line of welding engineering
  • Experience in solving wear problems for many years.

In-House hardfacing services

On-Site Services

Wear Resistant Plate – The Typical application of Hardfacing

The deposited wear plate is a dual-metal steel plate which manufactured by  overlay welding process. The wear resistant alloys were welded on the surface of Mild steel plate. This process is order to create a surface which can work at high wear conditions. It can be fabricated as the properties of mild-steel.

Download the D-Plate Introduction

The overlay welding process can be SAW, FCAW (Open arc), Sub-Arc Welding (The deposited layers can be made from calculated alloys using carbon electrode to melt weld pool). Depending each welding process, the width of welding seam will be difference.

(Wear plate surface)

Deposited wear plate can be made either Flat Process or Rotary Drum Process.

(Wear Plate manufacturing process – flat)


(Wear Plate manufacturing process – drum)

The deposited wear plate can be fabricated by various process, such as bending, cutting, welding, studding etc. Plate just can be cut (thermal cutting) by Plasma flame.

The deposited wear plate can be applied at many difference industries which contains difference wear factors, such as: Abrasion, Corrosion, Heat, Impact, etc. By changing the welding consumable (alloys), we can create a new product which is suitable for specific application.

Some typical industries: Cement, Coa-fired Power Plant, Mining, Quarrying…

Typical application of wear plate:

What is the hardfacing? Trends and Applications

1. General

Hardfacing is applied in cases where the surface of engine parts is being subject to abrasion by wear, corrosion or heat. According to the definition hardfacing is applied when the surface is going to be damaged by wear due to hard minerals.

This happens in all domains of mechanical processing, where processes are realised at room temperature or increased temperatures, such as in crushing, conveying, mixing and separating in the field of mining, steel and iron industry, cement industry, coal power plants, overground and underground working, recycling and environmental protection.

In chemical industry it is applied in areas of sharp mineral dressing.

The objective of hardfacing according to DIN 50320 is to surface a layer onto the basebody, which is most beneficially resisting to the wear-causing mineral.

The meaning of hardsurfacing did significantly increase in the course of the last 10 years, as standstills do become more and more expensive for big factories, due to increased wages and salaries, but also for reasons of networking. Layers of between 2 mm and 200 mm thickness can be produced by application of the different hardfacing procedures, whereas the fusion-efficiency rate can vary between 0,5 and 50 kg/hour, with fusion penetrations of between 0,5 mm and 10 mm.

The welding procedures can be differentiated by the intensity of mixture with the base body, which is usually increasing along with an increasing fusion efficieny rate.

Nearly all kinds of weldable materials can be hardfaced and mostly all types of known wear- resistant metals in combination can be used as hardfacing materials.

Ceramic materials, which can only be coated by spraying-on thin layers, cannot be hardfaced.

2. Trends for Welding

2.1 Stick Electrodes and Filler wires 

Stick electrodes will be further used, before all for reparation in built-in condition, as they can be processed not only in tub position. Anyhow, their low fusion-efficiency rate, which results in costs of more than 50 Euro per kg, is a disadvantage.

Filler wires can be regarded as an absolutely necessary welding process, with regard to a consumption per buyer of more than 1 ton of material per year.

The fusion penetration per burner is usually between 3 – 6 kg per hour, so that the costs per kg welding material are decreased to an amount of about 20 Euro per kg.

But this processing can almost only be easily used in tub position. This means, that the engine parts to be protected have to be moved accordingly, so that welding in built-in condition is often impossible.

The results of fusion efficiencies of the latest developments in the sector of filler wires where up to 15 kg per hour, so that the costs per kg welding material decreased to 10 – 15 Euro per kg.

It is most important for tubular-wire welding that removal by suction is made very carefully.

2.2 Plasmapowder-Hardfacing 

Plasmapowder-hardfacing made a triumphant march through hardfacing of valves for the motor car industry. A mechanical hardsurfacing at permanent operation was achieved, with very slight mixtures and good surface qualities, so that the material consumption was only half compared to the demand for continuous casting sticks as used before.

This procedure is also qualified for tungsten carbides, which are not added into the metal arc, but behind it, in order to have them gently inserted into the melt, without their dissolution, what is a second advantage. Thus a higher rate of tungsten carbides is achieved, which means a significantly better resistance to abrasive minerals compared to usual chromium carbides.

This processing, as a special procedure, is widely applied at Rheinbraun, but also for processing of oil sands and in oil mining. The trend for this area has not yet become obvious.

2.3 Submerged hardfacing

Submerged welding processes give us the chance of achieving fully mechanically even higher fusion efficiencies, compared to tubular-wire welding with open metal-arc, which often do achieve between 8 – 10 kg.

But when applying this process, using wire or band, it is nearly impossible to produce high-quality hardfacings. Therefore this process, within the scope of hardfacing, is meant for big construction parts, such as cones of blast furnaces, but also for regenerating of earth shifting units, especially in the Far East, whereas in Europe it seems to be more economic to use new parts, which are scrapped after their wear reserve has been exhausted.

Hardfacing is a wage-intensive process, which is only to be applied, where operation costs in Western European countries, where wages costs are high, can really be decreased by applying this technology, or when operativeness cannot be guaranteed in another way.

4 Application of prefabricated hardfaced plates

Instead of hardfacing the part by own production, semifinished hardfaced products are more and more used.

These polyburner-technology plates with a high fusion-efficiency rate can be produced much more economically than having them manufactured by own production.

Constuction parts, such as hoppers, chutes, screens, tubes, fans, separators or others, can be manufactures by plasma-cutting and forming of such plates.

3. Trends for Welding Fillers

3.1 Increased Application of titanium-carbide containing martensitic alloys

The main application of hardsurfacing was formerly the use of martensitic alloys with 400 – 600 Brinell, but nowadays such material contain titanium-carbide fortifications, although the removal of slag is quite difficult when using such addings. Especially when using these materials, or those where niobium is added to martensitic alloys, the application is recommended for wear problems of so-called high- pressure rollers in a wide range.

3.2 Use of highly-chromium containing materials with higher carbon contents then those of filler wires

Compared to formerly used hardfacing materials as filler wires, normally of the alloy group 10 with 4,5% C and 30% Cr, there is a clear trend towards higher alloyed filler wires to be seen, as only when using these filler wires as a second and third layer a significantly longer lifetime will be achieved.

In general such materials do contain 5,5% C, 20% Cr and 7% niobium, at higher temperatures they do also contain molybdenum and tungsten. In a certain range these materials can also be applied for higher temperatures up to ca. 750° C, but they will lose their wear-resistance at higher temperatures due to transformation of the matrix.

3.3 Tungsten-carbide containing hardfacings

In former times such materials were only used in oil- mining due to reasons of costs, whereas their application did meanwhile considerably increase, not only for stick electrodes, but also for filler wires and PTA- welding and special-welding procedures, as the lifetime is significantly higher, whereas the wages costs are the same. did meanwhile considerably increase, not only for stick electrodes, but also for filler wires and PTA- welding and special-welding procedures, as the lifetime is significantly higher, whereas the wages costs are the same.

But meanwhile there is a clear trend towards iron- containing materials, which are, as a consequence, cheaper.

4. Trends for Applications

4.1 Hardfacing of Strips and Disks for Coal- and Cement-Crushing

Application for Vertical Roller Mills in Cement Plant

Generally such strips do consist of materials which are known from the literature as being unweldable, having a high carbon-, chromium- or nickel-content.

Anyhow this is the second-largest application worldwide for hardfacing with chromium-containing hardfacing materials. Compared to casting materials, the achieved lifetime is twice or three times longer and the grinding result is much better for a long period of time.

In the same way the disk, on which the strip rolls, can thus be regenerated and the lifetime extended.

4.2 Sinter-crusher stars with cobalt-base alloys and inserted mixed carbides

Sinter crushers are a considerable wear problem in each iron and steel work worldwide. Generally their lifetime in hardfaced condition is about 2-4 months. Actually tests are made, in order to find out if the use of tungsten-chromium carbides can increase lifetime significantly, which are promising.

But with regard to bar frames (the counter-part) it already became obvious that with such materials a longer lifetime is not achieved, due to even higher temperatures.

4.3 Use of hardfaced Plates as semifinished Products

The main trend and most important application for hardfacing worldwide is the production of hardfaced plates in standard sizes, of which parts ready to be installed are being manufactured. Processes according to drawings of parts to be manufactured can be made of such hardfaced plates, using plasma- burners or water-jet.

Even complicated equipments can be made by cold- work, like some examples show. The cheap production of the semi-finished products is mainly interesting, whereas the welding mechanization is most important. This can be achieved by using special procedures with an extremely intensive fusion efficiency rate per burner, or by combining many burners, e.g. up to 10 burners for filler-wire weldings.

 

Hardfaced Wear Plate Producing

5. Trends as a Result of Environmental Protection Prescriptions

The environmental protection is a very important trend for hardfacing, which will cause much more problems in the future than it did the last 100 years. Steams are emerging whilst hardfacing, which are not that dangerous, as they do nearly not contain hexavalent chromium. The size of dust particles is dangerous, so that a good suction during work shall be ensured.

In addition, there are new trends coming up with regard to valuation of danger of nickel and manganese, which will probably afford high investments with regard to the suction of such welding-steams within the next 10 years.

For that reason we assume that in the future there will be a concentration of orders in less locations, where an excellent suction is guaranteed, or where in fully- enclosed cabins, supported by robots, the main hardfacing work will be done.

Summary

Hardfacing is a modern procedure, which nowadays is mainly applied for bigger construction parts, in order to extend the lifetime, instead of using massive solutions, such as castings. This “added value” makes the parts more valuable, and the demand for it will be constant, as the standstill of concatenated machines will become more and more expensive.

 

Innovative Alloys – All kind of flux cored wires

Innovative Alloys – IA – are a Flux-cored wire manufacturer specialized in producing hardfacing, cladding and joining wire for open arc, gas shielded or submerged arc welding process.

Download file  Innovative Alloys introduction

Our plant is equipped with Automatic powder sieving machine, mixers for wet and dry mixing of carefully control particles size for wire production. Baking oven for powders.

Automatic production line, wire rerolling line, wire drawing machine, wire popping machine, wire spooling machine and vacuum packed.

We produce wires the whole range of ferrous based hardfacing, cladding to your specification and application and we also provide private labeled. The range of application include Build up and buttering, low & medium alloyed for metal to metal wear at low and high temperature, abrasive resistance at low and high impact, work hardening at high impact.

We can produced wire range from 4.0mm down to 1.2mm and packed in 15kgs spool, 25kgs wire basket, 125kgs pop and 250kgs pop.

Download Product Catalogs

Welding for Repair and Surdfacing

Abstract:  Repair welding and surfacing are both considered in the field of maintenance welding and are covered together since they are both done by the same welders. Often it is extremely difficult to separate what is considered repair welding from maintenance welding, and surfacing can be included in both situations. The same basic factors apply to both weld repair and surfacing. Repaired parts may be more serviceable than the original part, since they can be reinforced and the weaknesses of the original part corrected. It is often more economical to weld repair since the delay in obtaining the replacement part could be excessive and the cost of the new part would normally exceed the cost of repairing the damaged part The need for weld repair and surfacing

There are probably more welders employed doing maintenance and repair welding than there are in any other industry grouping. The work done in the primary metal industry is primarily maintenance and repair. This is true also of the utility services category and by combining these with repair services you find that approximately 18% of the welders are engaged in this type of work. In addition, it has prime importance to welding since the earliest use of welding was for repair work. The most famous incident happened at the outbreak of World War I when German ships were interned in New York harbor. Their crews, hoping to make the ships inoperable, sabotaged the engines and machinery. However, by means of welding, repairs were quickly made and the ships were placed in transatlantic service to deliver material from the U.S. to Europe. Repair welding and surfacing are both considered in the field of maintenance welding and are covered together since they are both done by the same welders. Often it is extremely difficult to separate what is considered repair welding from maintenance welding, and surfacing can be included in both situations. The same basic factors apply to both weld repair and surfacing. Parts break and wear out continually. It may be impossible to obtain another part exactly like the one that broke or wore out. This is particularly true of older industrial machinery, construction machinery, agricultural machinery, machine tool parts, and even automobiles. Repaired parts may be more serviceable than the original part, since they can be reinforced and the weaknesses of the original part corrected. It is often more economical to weld repair since the delay in obtaining the replacement part could be excessive and the cost of the new part would normally exceed the cost of repairing the damaged part. Weld repair is commonly used to improve, update, and rework parts so that they equal or exceed the usefulness of the original part. This is normally attained, with the possible exception of weld-repaired cast iron parts that are subjected to heating and cooling. Weld repairs on cast iron parts subjected to repetitive heating and cooling may or may not provide adequate service life. The problem is that cast iron parts subjected to high-temperature heating and cooling, such as machinery brakes, furnace sections, etc., fail originally from this type of service and due to metallurgical changes the weld may fail again without providing adequate service life. Except for emergency situations, it is not wise to repair cast iron parts of this type. The metal that the part to be repaired is made of has a great influence on the service life of the repaired parts. Parts made of low-carbon and low-alloy steels can be repaired without adversely affecting the service life of the part. On the other hand, high-carbon steels may be weld repaired but must be properly heat treated if they are to provide adequate service life. It is absolutely essential that we know the type, specification, or composition of the metal that we are planning to weld. As mentioned above, it may be unwise to weld repair certain metals. But we should not weld on any metal unless we know its composition. The economics of weld repairing are usually very favorable and this applies to the smallest or the largest weld repair job. Some weld repair jobs may take only a few minutes and others may require weeks for proper preparation and welding. Even so, the money involved in a repair job may be less than the cost of a new part. A part made of any metal that can be welded can be repair welded or surfaced. In fact, some of the metals that are not normally welded can be given special surfacing coatings by one process or another. All the arc welding processes are used for repair and maintenance work. In addition the brazing processes, the oxy-fuel gas welding processes, soldering, thermit welding, electro slag welding, electron beam welding, and laser beam welding are also used. The thermal spraying processes are all widely used for surfacing applications. In addition, the various thermal cutting processes are used for preparing parts for repair welding. The selection of the appropriate preparation process and welding process depends on the same factors that are considered in selecting a welding or cutting process for the original manufacturing operation. In the case of repair welding, there are usually limitations, such as the availability of equipment for a one-time job and the necessity of obtaining equipment quickly for emergency repair work. This limits the selection and it is for this reason that the shielded metal arc welding process, the gas metal arc welding process, the gas tungsten arc welding process, and oxyacetylene welding and torch brazing are most commonly used. However, for many routine and continuous types of repair work some of the other welding processes may be the most economical. For example, submerged arc welding is widely used for building up the surface of worn parts. The electro slag process has been used to repair and resurface parts for hammer mills, for construction equipment, and for rebuilding rolls for steel mills. Thus there is a difference in the selection of the welding process for the routine, continuing types of repair and surfacing work versus the one-of-a-type or breakdown emergency repair job.

Analyze and develop rework procedure

The success of a repair or surfacing job depends on the thought and preparation prior to doing any actual work on the project. Many factors must be considered in making a thorough analysis. A thorough analysis as outlined may not be required in many situations. This is due to experience gained by welders and others in analyzing jobs, making repairs, and then checking on the service life of the repaired part. As experience is gained many short cuts can be taken, but it is the intent to provide a detailed method of analyzing jobs so that the repair will be as successful as possible. One of the reasons for such an investigation is to establish the cause of the failure in the case of a broken part or the cause of wear or erosion in the case of a part to be surfaced. The four points outlined are:

  • Make a detailed study of the actual parts that failed.
  • Learn the background information concerning the specifications and design.
  • Make an investigation of the materials used.
  • Make a listing of all of the facts so that at the conclusion the reason of failure will be as accurate as possible.

There are certain situations and certain types of equipment for which repair welding may not be done or may be done only with prior approvals. Certain types of containers and transportation equipment must not be weld repaired or may be welded only with special permission and approval. These include railroad locomotive and car wheels, high-alloy high-strength truck frames, and compressed gas cylinders. Most pieces of power-generating machinery, including turbines, generators, and large engines, are covered by casualty insurance. Weld repair on such machinery can be done only with the prior approval of the welding procedure by the insurance underwriters. In some cases, approval may not be granted. An example of this can be cast iron crankshafts in large stationary diesel engines. Certain weld repairs may be made but it is necessary to develop a written procedure which must be approved in writing by the underwriting company’s representative. Repairs by welding to boilers and pressure vessels require special attention. Pressure vessels that carry an ASME stamp or are under the jurisdiction of any state or province or government agency must be repaired in accordance with the National regulations issued by responsible authorities. Repairs by welding are limited to steels having known weldable quality. It provides a maximum carbon content of 0.35% for carbon steels and a carbon content of 0.25% for low-alloy steels. For welding high-alloy materials and nonferrous materials the work must be done in accordance with the ASME code. Welders making such repairs must be qualified based on the thickness of the material and the type of material being welded. Full-penetration welds are required with welding recommended from both sides. Permissible welded repairs are defined as cracks, corroded surfaces, and seal welding, patches, and the replacement of stays. A repair is the work necessary to return a boiler or pressure vessel to a safe and satisfactory operating condition. Alterations are also permitted and this is a change in a boiler or pressure vessel that substantially alters the original design and in this case work can be done only by a manufacturer possessing a valid certificate authorization from ASME. All alterations must comply with the section of code to which the original boiler or pressure vessel was constructed. A written repair procedure is required for doing either repair work or alterations. In the case of an alteration a record must be made and all alteration work must be approved. These records must be filed with the inspection agency or the jurisdictional agency, the National Board of Boiler and Pressure Vessel Inspectors, and all work must be inspected. Alterations on bridges, large steel frame buildings, and ships may be done only with special authorization. The alteration work must be designed and approved. The welders must be qualified according to the code used and the work must be inspected. Written welding procedures are required. Once the decision has been made to make a weld repair it is then necessary to establish why the part failed or wore out. This relates to the type of repair job since it also determines whether reinforcing may be required. Reasons for the part to fail or wear out can be among the following:

  • Accident
  • Misapplication
  • Abuse
  • Overload.

If the part failed because of an accident or an overload, it may be returned to service with the weld repair made to bring it back to its original strength. The same consideration applies if the part has been abused or misapplied. It may be necessary to reinforce the part so that it will stand temporary overloads, misapplication, or abuse. This decision should be made prior to the weld repair. In the case of poor workmanship, poor design, or incorrect material the weld repair should eliminate the poor workmanship that was responsible for the failure. In this case, the part would be returned to its original design. If failure is due to poor design, design changes may be required and reinforcement may be added. In a case of wrong material it will be assumed that the material was of a lower strength level which contributed to the failure. In this case reinforcing would be required. If the repair or alteration job is to modify the part, it is necessary that the modification be designed by competent designers who have the knowledge of the design conditions of the original part. This may require reinforcing to make sure the modification or alteration is satisfactory. Another important factor that must be considered is what results are expected of the repaired or reworked part. Should it be reinforced or should it be redesigned and altered to provide necessary service life? Finally, in the case of surfacing, what better surface could be provided to withstand the service that caused the premature wear or failure?

Rework Procedure

A written repair procedure is required for all but the most simple jobs. It is absolutely necessary that the type of material being welded is known. This can be found in several ways. If possible, refer to the drawing of the part and the specifications that are shown for the part or parts to be welded. If this is not possible, particularly in the field or at the maintenance shop, look for clues as to the type of metal involved. Analyze the application of the metal, for clues. For example, an automobile engine block is normally cast iron except for some which might be cast aluminum. Aluminum and iron are easily distinguishable. The spring of an automobile or truck would normally be high-carbon steel. The body structure of a car or truck would be mild steel. The appearance often helps provide clues. As a final resort it may be necessary to obtain a laboratory analysis of the metal. Filings or a piece of the metal must be sent to a laboratory capable of making such determinations. The normal method of selecting the welding process will be followed once the material to be welded has been identified. This involves the type of metal, the thickness of the metal, the position of welding, etc. This also leads into the question of filler metal to be used. After this, the normal method of filler metal selection is followed. This involves matching base metal composition, matching the base metal properties, particularly strength, and providing weld metal that will withstand the service involved. In surfacing, the surface characteristics desired for the finished job depend entirely on the service to which the surface will be exposed. This is based on knowledge and experience and on the fact that the surface has deteriorated to the point that it needs to be reworked or resurfaced. When wear is involved, surfaces can be rebuilt many times without reducing the strength of the part and the service life will be greatly extended. The repair procedure should be very similar to a procedure developed for welding a critical part. It should include the process and filler metal and the technique to be used in making welds.

Source: Internet

D-Parts – The belt housing fabrication based on wear plate

D-Plate have been using widely in many difference industries, such as Cement, Mining, Coal-fired Power etc.

With advantage of Wear Plate Producer, BCC has been providing the best solution in fabricating the wear parts based on D-Plate products. Especially, we are strong in producing the difficult-shapes parts, such as cone, pipe etc. Combining all factors, we can optimize the cost of final products by 20-30%. This is a big advantage for both BCC and his customers.

Below is a case study that we produce the belt housing parts for Loesche Mill LM53.3+3 which supply to Cement plant in 2015, 2016 and 2017.

Job details

  • Industry: Cement
  • Equipment: Vertical Roller Mill
  • Parts: Belt Housing
  • Product in use: D-Plate 8+5mm / 10+5mm

Some job photos