|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
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.
Click image to enlarge!
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
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
The welding processes we employ include Sub-arc, Gas shielded solid
wire, Gas shielded flux cored, Metal cored wires and Open arc
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.