Summary Projects Gc 2006 2012 Rev02
- 1. Advanced Weld Overlay Solutions State-of-the-art Hardfacing for Critical Mechanical Components Guy Chouinard, M.Sc., Eng. Revision 02 - 2012
- 2. Modern Weld Overlay Technologies Limitations of Common Hardfacing Techniques Welding usually involves considerable heat input and base metal dilution, often leading to metallurgy issues and distortion of the substrate. Conventional hardfacing techniques do not allow for precise thickness control under 1/8’’ (3 mm) and typically lead to high finishing costs. Well-known techniques such as stick electrodes (SMAW) and MIG (GMAW/FCAW/MCAW) often cause high reject rates due to overlay defects.
- 3. Modern Weld Overlay Technologies Self-Regulated Short-Circuit MIG Process (Rapid Arc) Molten Metal Transfer Modes MIG Weld Overlay Process Conventional MIG Rapid Arc Process Spray transfer mode SRSC mode
- 4. Modern Weld Overlay Technologies Self-Regulated Short-Circuit MIG Process (Rapid Arc) Higher cooling rate for easier position welding, a finer metallurgical structure and higher hardness for a given material, as well as more bead profile control. Minimum heat input for avoiding dissolution of hard phases, reducing the base metal dilution rate (3-5%), and lowering the work piece distortion levels. Most stable arc and metal transfer because of a self- regulated balance of inductance and capacitor discharge. Improved productivity. Less welding defects.
- 5. Modern Weld Overlay Technologies Self-Regulated Short-Circuit MIG Process (Rapid Arc) 10X Typical tungsten carbide nickel bead 200X
- 6. Modern Weld Overlay Technologies Better Control of Heat Input and Heat-Affected Zone High-carbon steel railway bearing box Gray iron pump plate and impeller Machinable carbon steel build-up Nickel-iron build-up and hardfacing HEAT-SENSITIVE BUILD-UP WORKS AND CAST IRON REPAIRS
- 7. Modern Weld Overlay Technologies Improved Deposition Rate and Cost-Effectiveness Steel mill furnace table feed rolls Aggregate crusher blow bars COMBINED IMPACT AND HIGH-STRESS WEAR WKP-1600-TC TiC-enhanced martensitic steel
- 8. Modern Weld Overlay Technologies Reduction of Common Weld Defects Occurence Extruder valve stem – Stellite® 6
- 9. Modern Weld Overlay Technologies Lower Dilution Rate and Enhanced Material Properties Steel making continuous casting roller Nitrogen-enhanced advanced stainless steel
- 10. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA) 0.040’’ (1.0 mm) to 0.160’’ (4.0 mm) per weld pass
- 11. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA) Significant improvements over original design introduced by Deloro-Stellite in 1962 and commercialized thereafter. Competes with laser cladding in terms of precision, repeatability and metallurgies - Introduction of inverters (pulsed current) and robotics. Also capable of relatively high deposition rates (10 kg/h) with lower amperage and consumable cost than ever - Improvement of torch design. Possibility of conducting hardfacing works in an inert gas positive pressure container, mostly for applying titanium and refractory metal overlays.
- 12. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA)
- 13. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA)
- 14. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA)
- 15. Modern Weld Overlay Technologies Enhanced Plasma Transferred Arc Process (ePTA) Internal composite hardfacing capabilities Starting at 4’’ (100 mm) inner diameter
- 16. Advanced Materials Strategy Wear-Resistant Materials – Self-fluxing Nickel Alloys CEMA screw coupling shafts 60-HRC NiCrSiB ePTA hard coating Slurry control valve ball and stem 50-HRC NiCrSiB ePTA hard coating
- 17. Advanced Materials Strategy Wear-Resistant Materials – Cobalt-based Alloys ASTM A-182 F9 alloy steel 30-in ball valve seats Stellite® 21 and Stellite® 6 dual ePTA hardfacing Iron content below 5% - ASME Code Section IX
- 18. Advanced Materials Strategy Wear-Resistant Materials – Chromium Carbide Irons WKP-1055 ePTA hardfacing 100 X 500X 53-55 Rockwell C 500X Advantages of ePTA chromium carbide hardfacing over FCAW: Random carbide precipitation at ~100 m above interface - Harder microstructure Typical base metal dilution zone is ~500 m thick - First layer with full hardness
- 19. Advanced Materials Strategy Wear-Resistant Materials – Chromium Carbide Irons WKP-1058 ePTA hardfacing 56-58 Rockwell C WKP-1068 ePTA hardfacing 66-68 Rockwell C
- 20. Advanced Materials Strategy Wear-Resistant Materials – Tungsten Carbide Composites Typical ePTA tungsten carbide nickel hardfacing Rolling mill conveyor roll WK-0600S ePTA tungsten carbide nickel
- 21. Advanced Materials Strategy Wear-Resistant Materials – Tungsten Carbide Composites Anode paste continuous mixers Tungsten carbide nickel hardfacing
- 22. Advanced Materials Strategy Wear-Resistant Materials – Tungsten Carbide Composites Silicium metal crusher feed rolls WK-0601A tungsten carbide nickel Iron ore green pellets crusher rolls WK-0600S ePTA tungsten carbide nickel
- 23. Advanced Materials Strategy Wear-Resistant Materials – Tungsten Carbide Composites TiO2 pigment dry pump screw and sleeves WK-0600S ePTA tungsten carbide nickel
- 24. Advanced Materials Strategy Wear-Resistant Materials – Tungsten Carbide Composites Copper smelting converter injection tuyeres (43 mm ID x 60 mm OD x 1200 mm – 20-40 tph) WK-0600S ePTA internal hard coating
- 25. Turnkey Project Solutions Hard Materials Engineering and Processing
- 26. Turnkey Project Solutions Hard Materials Engineering and Processing Backfill sludge pump wear plates and rings WK-0600S ePTA tungsten carbide nickel
- 27. Turnkey Project Solutions Process Equipment Re-manufacturing Thick-stock pump rotor segments Stellite® 6 perimeter repair Wood chip plug screw feeder 45-HRC self-fluxing nickel alloy
- 28. Turnkey Project Solutions Custom Chromium Carbide Wear Plates WKP-1055 chromium carbide wear plates 55-59 Rockwell C Iron ore sintering exhaust fan casing
- 29. Turnkey Project Solutions Custom Overlaid Slurry Pipes and Fittings Concentrator slurry pump discharge reducers WK-0601A ePTA tungsten carbide nickel
- 30. Turnkey Project Solutions Tungsten Carbide Nickel Arc Spray Coatings Iron ore exhaust fan inlet bell