Hardsurfacing and Weld Reclaim

The cost advantage of salvaging worn parts by welding is recognized by many industries. Depositing a more noble metal on a component made from a less expensive material is also an established practice. The three main applications are to guard against impact, abrasion, corrosion or a combination of these wear factors.

An analysis of the cause of wear is the most important step in surface technology. In many cases, welding is the most cost effective way to apply the protective material. Unfortunately, many applications are unsuccessful due to incorrect welding procedures. Established welding procedures must be followed.

One of our N.C. controlled welding centers. The rotator can turn 1.6 meter diameter components between 3 meter centers with a weight of 5 tonnes. The welding machine, a Lincoln Synergy 7 with syncro pulse is programmable and has a potential of 450 amps at 100% duty cycle.

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In order to control the welding parameters as closely as possible, we employ robotic welding centers. Our largest manipulator can hold 5 tonne components between 3 metre centers. A diameter of 1.5 metres can be turned. The manipulator is interfaced with a Motoman robot, covering a floor space of 3 meters in diameter.

We also use a W.A. Robotrak welding unit. This covers an area of 4 meters wide by 2.4 meters high and 8 meters long. Using a simple x,y,z, axis controller, we have welded components up to 10 tonne.

The welding processes we employ include Sub-arc, Gas shielded solid wire, Gas shielded flux cored, Metal cored wires and Open arc wires.

The welding power sources include a constant voltage Hobart delivering 650 amps @ 100% duty cycle and the latest state of the art Lincoln Synergic 7 Synchro Pulse unit delivering 450 amps @ 100 % duty cycle.

Our most important asset is the knowledge of the welding metallurgy held by our staff. This is particularly important when overlaying complex alloys. We are currently involved in the overlaying of Continous Casting plant rolls using Nitrided 414 alloys. The substitution of nitrogen for carbon has shown greater life for rolls in severe conditions.