Patricio Mendez, University of Alberta

Bio: Prof Mendez is the Weldco/Industry Chair in Welding and Joining and Director of Canadian Centre for Welding and Joining at University of Alberta. Before joining the University of Alberta in January 2009, he taught and researched at the Colorado School of Mines. Before that, he was a consulting engineer at Exponent Inc. In 1995 Dr. Mendez co-founded Semi-Solid Technologies Inc. in Cambridge, MA. Prof. Mendez holds a Ph.D. and a M.S. degree in Materials Engineering MIT, and a Mechanical Engineer degree from the University of Buenos Aires. Among his distinctions are the IIW Kenneth Easterling Award, AWS William Spraragen Award, Charles H. Jennings Award, and Silver Quill Award, and the NSF CAREER Award.

MODERN TECHNOLOGIES FOR THE DEPOSITION OF WEAR-RESISTANT OVERLAYS

This presentation will focus on equipment and metallurgical issues in the deposition of wear-resistant overlays. The focus will be on the nickel-tungsten carbide and chrome carbide overlays for the oil sands, with an emphasis on current work performed at the Canadian centre for Welding and Joining (CCWJ). For nickel-tungsten carbide, current efforts to implement tubular-wire based processes will be described, comparing several wires available in the province, deposition technologies, and technological challenges. While dissolution is a well known challenge in nickel-tungsten carbide systems, the recent discovery of carbide bouncing off the free surface of the molten metal is novel and crucial to understand the process. For chrome carbide overlays, microstructural development and actual microstructure will be discussed. Significant differences with white cast irons will be highlighted, including the layered structure of the overlay, the effect of cooling rate, and the effect of dilution and segregation. Advanced tools for imaging and image recognition used and developed at the CCWJ for analysis of overlays will also be described. Stuart Guest, Steven Borle, Gentry Wood, Matt Dewar, and Goetz Dapp are coauthors of this work.

Cost: Members $250, Non members $325, Students $25, Teachers $75Please note that attendees will earn 0.4 CEU credits OR 4 hours toward professional development credits.

Address: University of Alberta – ETLC Building/ ETLC Solarium. 9107 – 116 Street, Edmonton, AB T6G 2V4

May 16, 2013 • 6 Speakers from 8AM to 5PM

Weld Overlays for Wear Protection

This is a CWA National Event presented in conjunction with the Edmonton Chapter

Ravi Mennon, VP/General Manager of Victor Technologies

Bio: Dr. Ravi Menon is the Vice-President and General Manager of the Stoody Company, a division of Victor Technologies. Dr. Menon received his Bachelors and Masters degrees in Metallurgical Engineering from the Indian Institute of Technology, Madras, India and his PhD from the University of Tennessee, Knoxville, USA. He has over 25 years of experience in the design of welding consumables for high alloy welding and hardfacing. He was the Director of Technology at Teledyne McKay for six years and was responsible for product development Stoody for the past fifteen years before taking on the new responsibility. He has been involved extensively in designing hardfacing consumables for mining and oil sands pipe ID cladding, steel, power generation and cement industry applications.

HARDFACING WITH CHROMIUM AND TUNGSTEN CARBIDE OVERLAYS –CURRENT STATE OF THE ART

Chromium Carbide overlaying with flux cored wires makes up the largest segment of hardfacing using the welding process. These wires are of relatively low cost and provide a wear resistant surface that has a low stress abrasion resistance more than ten times better than that offered by mild steel (as measured using the ASTM G65 low stress abrasion test). Wire diameters are available in the range from 0.035” (0.9mm) to 1/8” (3.2 mm) offering a wide range of applicability as well as heat input and puddle control. The paper will cover the most commonly utilized compositions of the 5C-25Cr type and also discuss modifications to the alloys with additions of secondary alloying elements such as niobium, molybdenum and boron. The improvement in wear properties specific to the oil sands applications such as slurry jet abrasion will be discussed. The importance of controlling wire composition and welding process control to achieve overlays suitable for pipe ID cladding will also be covered. The paper will also discuss the design of newer alloys that offer a higher degree of wear resistance as well as better protection against a corrosive-erosive environment. In addition, the development of nickel based wires that incorporate tungsten carbide resulting in a significantly higher degree of wear resistance under extreme wear conditions will be discussed. The applicability of these wires for high wear components using conventional and well as synergic power sources will be highlighted.

Douglas J. Hamre, R&D Manager of Appolo-Clad Laser Cladding Ltd.

Bio: Douglas J. Hamre is currently the Research and Development Manager at Apollo-Clad Laser Cladding Ltd. (A Division of Apollo Machine & Welding). Originally from Edmonton, Doug attended the Colorado School of Mines in Golden, Colorado, where he received a B.Sc. in 2001 and a Ph.D. in 2005 both in the field of Metallurgical and Materials Engineering. Doug returned to the Edmonton area in 2011 to join Apollo-Clad after working in the investment casting industry making Titanium and Superalloy castings for aerospace and power generation applications. Doug is also registered as a Professional Engineer in the province of Alberta.

LASER APPLIED TUNGSTEN CARBIDE WEAR PROTECTION (LASER CLADDING)

Laser Cladding is a relatively new process in the world of welded wear protection overlays. Recent advancements in laser technology have allowed for more production friendly systems that can provide a beneficial cost to performance ratio for high quality wear resistant coatings. The high energy density of the laser welding process allows for a high travel speed and controlled melting of the base material (ie: very low total heat input). Through carefully selected and controlled parameters, a minimum amount of base material is melted while powder is delivered to the weld pool. The result of the low heat input is minimal dilution in a single pass weld and minimal distortion, even in relatively thin walled components while maintaining a metallurgical bond with the substrate. Minimal melting and dilution allows for welding of dissimilar materials, and welding of traditionally difficult to weld materials. The typical microstructures developed during laser cladding will be discussed along with the resulting properties of the laser clad material. From a wear protection perspective, a laser clad spherical fused tungsten carbide overlay in a Ni-based matrix will have an ASTM G65 mass loss of less than 0.05 g. Additional examples of field proven wear protection capabilities will also be discussed.

Petr Fiala, Materials R&D Manager of Sulzer Metco (Canada) Inc.

Bio: Petr Fiala, PhD, is the Materials R&D manager at Sulzer Metco (Canada) Inc. Petr obtained his Masters and Postgraduate Degrees in Materials Engineering from the University of West Bohemia with thesis on thermal barrier coatings and HP/HVOF sprayed chromium carbide coatings, respectively. Petr has been working on research projects dealing with hardfacing, abradables, and thermal barrier coatings for 20 years and since 2007 he is mostly focused on developing powders for plasma transferred arc welding and laser cladding. He is a long time member of ASM International.

TUNGSTEN CARBIDE AND ITS USE IN PTA AND LASER CLAD OVERLAYS

Tungsten carbide containing overlays are used as a preferred technical solution in many wear applications. The presentation will provide an overview of the history of tungsten carbide production and its use in surface protection. It will continue with a description of tungsten carbide properties, and explain differences among various types of tungsten carbide which originate from its chemistry, manufacturing method, and further processing. The main focus will be on examples of tungsten carbide usage in PTA (plasma transferred arc) and laser clad overlays in various applications. Several widely used compositions will be presented in more detail.

HIGH POWER FIBER LASER WELDING APPLICATIONS IN INDUSTRY

In recent years, with more attention being focused on the economy, manufacturing has come under increasing pressure to offer more cost competitive solutions. Globalization and the rising cost of labour have placed increasing pressure on companies to automate and offer faster yet more accurate processing. With the inception of the Fiber laser technology, fiber lasers have reduced the price of the one micron wavelength to approximately one third of the 2006 prices. This reduction is also complimented by higher laser reliability and minimal heat affected zone. Laser welding is now at the forefront of many markets including mining, automotive, medical, and nuclear and includes cladding, welding, and heat-treating. This presentation focused on the welding process, its benefits to future welding techniques and current implementations.

Chris Pilcher, Regional Sales Manager of IPG Photonics

Bio: Chris Pilcher is the Regional Sales Manager for IPG Photonics in Canada, the largest supplier of Fiber lasers worldwide. He has held similar positions at Trumpf Canada and Rofin-Sinar. In addition, Chris was President and CEO of Welding and Cutting Solutions who were responsible for integration and installation of specialized systems. Mr. Pilcher served as the Director of Automation and Engineering Manager at Liburdi Automation Incorporated. He has over 25 years experience in the welding and systems integration field and holds a degree in Mechanical Engineering from the University of Waterloo, as well as, a degree in Computer Science. His experience has spanned many industries including Nuclear, Aerospace, Automotive, Mining and Medical.

Stefano Chiovelli, Senior Technical Associate Mettalurgical Engineer of Syncrude

Bio: Stefano graduated from the University of Alberta in December 1986 with a B.Sc. in Metallurgical Engineering . He began working at Syncrude in 1987 in the Quality Assurance department working in the Mining and Secondary Upgrading areas. He joined NOVA Gas Transmission in 1991 as a Failure Analyst and returned to Syncrude Research in 1993. Stefano has been involved in a wide range of wear, corrosion, fitness for service, non-destructive testing and welding issues at Syncrude’s operating plants. In 1999 he received an M.Eng in Welding Engineering from the University of Alberta and is an International Institute of Welding(IIW) International Welding Engineer. He is a member of the Professional Engineers, Geologists and Geophysicists Association of Alberta (APEGGA).

IMPROVING RELIABILITY AND PRODUCTIVITY THROUGH MATERIALS AND DESIGN

Development and application of wear protection in the oil sands has been an on going challenge due to the abrasivity of the material and the massive volumes of materials that are moved. In order to effectively battle the different wear and corrosion mechanisms that lead to material loss, it is important to understand how materials behave in the environments in which they are used. The use of various materials and application processes along with component design modifications can result in significant improvements in both productivity and reliability. This presentation will discuss the main wear mechanisms typically found in the mining and processing of oil sands. How these damage mechanisms can be addressed will also be discussed.

Dr. Andreas Kirsten, RESEARCH AND DEVELOPMENT - C&M TECHNOLOGIES GMBH, IMMELBORN / GERMANY - MANLUK MINING INC.

Bio: Dr. Andreas Kirsten completed his studies in Materials Engineer in 1992. In 1996 he graduated with a PhD degree in Material Science from Technical University “Bergakademie” Freiberg. From 2000-2006 he worked as assistant professor at University of Federal Armed Forces in Hamburg in R&D for WOKA and from 2003 for Sulzer Metco WOKA with focus on carbide containing powders for HVOF and PTA and electrochemical corrosion studies of HVOF- coatings. Today Andreas is responsible for R&D at C&M Technologies, a manufacturer of carbide based hard-facing materials for welding, PTA-welding and HVOF-spraying.

PLASMA TRANSFERRED ARC WELDING WITH CARBIDE BASED POWDERS – APPLICATION AND MATERIALS

Wear protection is a still increasing branch of surface technology. Under the conditions of heavy wear attack, like in mining, often thick coatings with high wear resistance and sufficient wear reserve are required. In such cases the PTA-welding technology with carbide based materials has many advantages compared to other welding techniques. The sensible adjustable energy input and the very low welding penetration makes it possible to apply hard composites with up to 65% primary tungsten carbides. Manluk Corporation is one of the market leaders in Canada extensively using PTA with tungsten carbides to supply the oil sands industry. Manluks current capabilities include a total of 2 (two) Semi-Automatic, 9 (nine) Automatic and 3 (three) fully-automated (Robotic) PTA Machines. Total potential working capacity equivalents to 336 hours per day. Manluk’s Standard PTA product line includes various types of Impact and Non-Impact Vibrating Screens, Rotary Breaker Screens, Crusher Segments which include Bases and Teeth, Cast Impacts, Wear Plates, Wear Bars, Wear Blocks, Knife Holders, Seats, Gates - both slab and expanding styles, flow deflectors and guage blocks. All of which vary in different types of overlay, overlay thickness, sizes and shapes. C&M Technologies is a manufacturer of hard-facing materials based on carbides for several surface technologies, e.g. welding, PTA and thermal spraying. The presentation gives an overview about the PTA process, shows some typical applications for PTA with tungsten carbides and gives an overview about the materials and their possible adaptations to certain demands in wear protection.

SCHEDULE

8:00AM - 8:30AM Registration & Continental Breakfast8:30AM - 8:45AM Opening Remarks and Introductions8:45AM - 9:20AM Speaker: Patricio Mendez, University of Alberta Topic: Modern Technologies for the Deposition of Wear-Resistant Overlays9:25AM - 10:00AM Speaker: Ravi Mennon, Stoody Topic: Hardfacing with Chromium and Tungsten Carbide Overlays 10:00AM - 10:20AM Break10:20AM - 10:55AM Speaker: Petr Fiala, Sulzer Metco Topic: Tungsten Carbide and it’s use in PTA and Laser Clad Overlays11:00AM - 11:35AM Speaker: Douglas Hamre, Apollo Tool Topic: Laser Applied Tungsten Carbide Wear Protection (Laser Cladding)11:40AM - 12:15PM Speaker: Chris Pilcher, IPG Photonics Topic: High Power Fiber Laser Welding Applications in Industry12:15PM - 1:00PM Lunch1:00PM - 1:45PM University of Alberta Lab Tour1:50PM - 2:25PM Speaker: Dr. Andreas Kirsten, Manluck Topic: Plasma Transferred Arc Welding with Carbide based Powders Application & Materials2:25PM - 2:45PM Break2:45PM - 3:20PM Speaker: Stefano Chiovelli, Syncrude Topic: Improving Reliability and Productivity through Materials & Design3:20PM - 4:20PM Closing and Networking

REGISTRATION

The registry contact is Bruce Cormier (bruce@grbwelding.com) or 780-436-7342. You can also register online at: www.cwaevents.org

Please provide number of reservations requested, name or names, company name, membership affiliation and phone number. We thank you in advance and are looking forward to your early registration.

Who should attend:

Operators, engineers, QC managers, suppliers, and users of products involving wear protection overlays for oil sands applications. Anybody who needs to deal with chrome carbide or tungsten carbide overlays, whether specifying or manufacturing products.

What will be discussed:

This one-day seminar will focus on what chrome carbide and tungsten carbide overlays are, their properties, performance, and features to observe. Consumables, processing, applications, and challenges in manufacturing will be discussed in general terms so participants learn the basics to make selections and decisions of consumables and processes.

Registration and Schedule Information

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Map & Parking

Parking: Windsor Car Park OR 116 St. & 92 Ave - If using the Windsor car-park you can use the entrance of the ECERF building. Take the elevator to the 2nd floor. When you pass Tim Hortons, Pizza 73 and the Subway, you will see the pad-way to the NREF building. Just on your left side is a huge area surrounded with glass.

University of Alberta ETLC Building/ ETLC Solarium. 9107 – 116 Street

Edmonton, AB T6G 2V4

Parking Hours - 6:00AM to 4:30PM - $14.00 all day parking(credit cards are accepted)

Parking at Windsor Car Park

SeminarLocation

2013CWA Conference • Oct 27-29 • Niagara Falls

Automotive • Manufacturing • Mining • Steelmakingwww.cwaconference.org

Chapter Chapter Chairs Email

BC Keith Neufeld keith@skcsiu.comCairo Atef H. ELSeify minamar13@hotmail.comCalgary Cory Slack CSlack@esab.comEdmonton Bruce Cormier bruce@grbwelding.comFort McMurray Paul Walters waltersp@FT-SERV.COMGolden Triangle Jason Ryan jasonryan@sympatico.caHalifax Jim Reid jim.reid@cwbgroup.orgHamilton Don Gemmell dgemmell@niagaracollege.caMontreal Martin Daignault martin.daignault@cwbgroup.orgNew Brunswick John Fisher John.Fisher@gnb.caNortheastern Ontario Robert Campeau rcampeau@ccmgroup.comNova Scotia Tony Rose Tony.Rose@nscc.caOkanagan VACANT VACANTOttawa Ken LeClair inspection@bell.netRegina Tracy Lippai tlippai@brandt.caSaskatoon Darcy Yantz darcy.yantz@cwbgroup.orgSoutheastern Ontario Greg Doria Greg_Doria@lincolnelectric.comSouthwestern Ontario Ian Cross Ian.Cross@valiantmachine.comNewfoundland & Labrador Brad Forsey bforsay@gjcahill.comSudbury Chapter Robert Campeau rcampeau@ccmgroup.comThunder Bay Victor Cooke vic.cooke@airliquide.comToronto Victor Andrisani Victor.Andrisani@AirLiquide.comUniversity of Alberta Steven Borle sborle@ualberta.caUniversity of Waterloo Ali Nasiri amnasiri@uwaterloo.caWinnipeg Bill Sutton bsutton@mwpltd.ca

CANADIAN WELDING ASSOCIATION8260 PARKHILL DRIVE • MILTON, ONTARIO • L9T 5V7

http://www.cwa-acs.org/