02 welding repair on steel and cast iron

7/30/2019 02 Welding Repair on Steel and Cast Iron

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Indonesian Welding Society (IWS)Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services

Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835Email: [email protected]

By Sabandi


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By Sabandi

Abstract

Some electrode special designed for welding repair and maintenance

On heavy equipment part , industrial equipment and dril ling equipment foroil and gas industries.

Problem on repair welding on heavy equipment part , industrial

equipment and drill ing equipment for oil and gas.

Cracking when welding or delay cracking.

Shrinkage Stress

Hardness in (HAZ) Heat Affected Zone.

Need PREHEATING before welding.


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The needed for pre-heating increases with following factor bellow :

Carbon content on Base Material

Metal Alloy on Base material

Dimension of Base Material (thickness etc)

Initial temperature

Welding speed

Diameter of consumableDetermine the pre-heating temperature based on carbon equivalent

of chemical composition on Base Material.

Ceq

= %C + %Mn /6 + (%Cr + % Mo + %V) / 5 + (%Ni + %Cu)/15

If Ceq increase , Pre-Heating needed increase


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CONTROLLING WELD METAL DILUTION

Dilution is the inevitable mixture of the base material and weld metal

deposit when welding

The objective is to keep the dilution as low as possible to obtain the

optimum properties in the hardfacing deposit

DilutionArea


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Factors influencing dilution

1. Welding Seed (Slow speed Dilution , High speed Dilution )

2. Welding Polarity

DCEN Low Dilution

AC Intermediate Dilution

DCEP High Dilution

3. Heat Input

Low HI Low Dilution

High HI High Dilution

4. Welding Technique Stringer beads Low Dilution

Weave beads High Dilution


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Buffer Layer are used asintermediate deposit between thebase material and the actualHard facing weld metal to : Ensure good bonding with the

base metal Avoid hydrogen-induce underbead cracking even onpreheated work pieces.

Minimize consequences ofStress

Limit the effect of dilution. Prevent possible crack in the

hard-facing layer running intothe base material.

Buffer Layer / Buttering

USE AUSTENITE CONSUMABLE FOR

BUFFER LAYER


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By Sabandi

WELDING CAST IRON

Cast iron is alloy iron with carbon withcontent %C 2-5 % , Silicon 1-3 % andmanganese 1%.Characteristic cast iron low ductility, lowhardness, low strength and generally avery bri ttle material. To improve theseproperties, cast iron is very oftenalloyed or heat-treated.

The type cast iron mainly used to day :Grey IronNodular IronMalleable IronCompact GraphiteWhite Iron


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Electrode for repair Cast Iron

1. Pure Nickel Type electrode

2. Nickel-iron type electrode

3. Nickel-cupper type electrode


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WELDING MANGANESE STEEL

Manganese steel some time calledaustenitic manganese steel withcontain %C 1- 1.4 % and 11-14 %manganese.

Characteristic Manganese Steel.Ability to Work harden during coldworking

High ImpactHigh surface pressure

Usually manganese steel used forCrushing and mining industry forexample crusher hammer, tumbler,bucket, digger teeth and rail point. Repairing chrusher 14% Mn

steel


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By Sabandi

The weld abil ity of manganese steel is restricted by its tendencyto become brittle upon re-heating and slow cooling.One rule of tumb is that the interpass temperature must notexceed 200 oC

CONTROL HEAT INPUT During welding essential.

Technique welding for Manganese SteelLow Heat input welding ( Low Current)Stringer bead welding

Speed cooling

Electrode for Joining AWS 5.4 E 307-16 (C=0.1 , Cr=18%, Ni=9%)

Electrode for Hardfacing / Surfacing , Buffer layer with AWS E

307-16 and hardfacing with E 7-200-K (%C= 1.1 and Mn = 13% )


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Sample of repair work

Crusher teeth Buffer layer E 307-16 , hardfacing E10-60 (OK84.78) %C 4.5 & Cr 33%, welding process SMAW


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Re-Build Crusher Hummer (OK 15.65) DIN 8555 compositionC 0.9%, Si 0.4%, Mn13%, Ni 3% Welding Process FCAW


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Hardfacing Support Roll

Buffer layer (OK 84.52)

DIN 8555 composition C0.25%, Cr 13%,

Hardfacing AWS 5.13ECoCr-A (OK 93.06)

Welding Process SMAW


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Hardfacing Teeth Exapator (OK 84.58) %C 0.7, Si 0.6%, Mn0.7% & Cr 10%, welding process SMAW


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Hardfacing Tumbler (OK 84.84) %C 3.0, Si 2.0%, Cr 8.0%, V6.0% & Ti 6.0%, welding process SMAW


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Repair Oil & Gas Drill Tools

Stabillizer drill tool, build up 304L powder andHardfacing Tungstent Carbide welding Process

PTAW


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Before Repair

After Repair

Repairing Drill Bit

Built up OK 83.28

(C 0.1% & Cr 3.2%)

Hardfacing

OK 84.84 (E 10-60-

GP)

Welding ProcessSMAW


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Rail Repair

Mould Welding OK 74.74


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Tram Line Repair

Electrode AWS 5.4307-15 (OK 67.52)

Composition :

C 0.1%, Mn 6%, Cr18%, Ni 9%

Welding ProcessSMAW


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Wheel Burn Repair

Filler OK Tubrodur 15.43

composition : C 0.15%, Cr1.0%, Ni 2.3% and Mo 0.5%

Welding Process FCAW


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By Sabandi

THANK YOU

02 welding repair on steel and cast iron

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