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Application - Cast Iron Repair
Application - Cast Iron Repair
Application - Cast Iron Repair
PAGE 2
BSW REPAIR APPLICATIONS
INDEX
PART
PAGE
PART
PAGE
11
Gearbox housing
Grooving
Arms
Gouging
Augers
15
Hammers
Bearing housing
Boiler tubes
13
Idlers
Bucket
Impellors
13
Bucket teeth
Jaw crusher
Cast-iron housing
Metal preparation
10
Chassis
10
Pump housing
10
Pump shaft
12
3/4
Rotor shaft
12
Coal Pactor
Screw
15
10
Shafts
12
10
Sprocket
Conveyor screw
15
13
Crane
Tube bend
13
Crusher Hammer
Tube protection
13
Crusher Jaw
13
Crusher rotor
15
Crusher shaft
12
Truck pads
Dozer blades
Valves
14
Extruders
15
Wear Plates
11
Exhaust fan
11
Fan blades
11
Worms
15
Flame brazing
15
Frames
Gears
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Machine: Excavator/Bulldozer
Part: Buckets/Dozer blades
Basematerial:Un/low alloy steel
Problem:
Wear on bucket and bucket teeth due to abrasion ,friction and impact by coal, sand, stone etc.
Equipment looses efficiency, causing increase in
operating costs.
Recommended Solution:
Protect bucket lips, sides and other wear areas by
applying a wear resistant high alloy Chromium
Carbide material.
Welding process: SMAW (stick electrodes)
BENEFIT:
prolong lifetime of equipment up to 300 %
Increase efficiency, reduce power consumption
PAGE 4
BUCKET TEETH:
Base material: Austenitic Manganese steel/Cast steel
Problem: teeth heavily worn
Solution: Cut spring steel to size and weld to worn teeth using Stick electrode or Wire
PAGE 5
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BSW ANTI WEAR TECHNOLOGY
Welding Tips:
Asses Analysis of base metal
Choose suitable filler material
Preheat accordingly.
Consider type of wear (metal/metal etc)
Rebuild Idler
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BSW REPAIR
JAW CRUSHERS
Are used to crush (reduce) hard materials such as coal,
stone etc.
The materials are crushed between Crusher Jaw plates
normally made form a wear resistant Manganese steel.
The high impact and compression causes the Jaw
plates to wear out and the crusher looses crushing
efficiency.
Replacement of crusher Jaw plates is often difficult,
time consuming and new jaw plates are expensive.
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BSW ANTI WEAR TECHNOLOGY
Problem:
The Hammers crushing the raw materials are
subject to extreme impact/pressure and abrasion and tend to suffer wear and tear making
the crusher machine inefficient.
Depending on the application such hammers
can be made from austenitic manganese steel
or low alloy cast steel.
EXAMPLE OF WORN CRUSHER HAMMER
SOLUTION and Recommendation.
1) increase lifetime(2-4times) of crusher by
applying 1 to 2 layers of gold 750 on new
hammers. Apply to wear areas.
2) Rebuild worn hammers by using one of the
following Welding materials.
A) Gold 710 a low alloy low cost electrode for
restoring dimension (within 2 layers and
thereafter apply 2 layers of gold 750 or 760
for maximum protection
B) Gold 740
for rebuilding and hardfacing.740 is a austenitic high alloy electrode and will provide best
long term result.
For best resistance use 750 or 760 as a
top layer.
All the above mentioned products are also
available for semiautomatic welding.
(FCAW) gas shielded or open arc
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BSW REPAIR APPLICATIONS
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BSW REPAIR APPLICATIONS
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BSW ANTI WEAR TECHNOLOGY
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BSW REPAIR APPLICATIONS
Axle shafts
Cam shafts
Crank shafts
Drive shafts
Crusher shafts
Pump shafts
Rotor shafts
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BSW ANTI WEAR TECHNOLOGY
Part: Impellor
Base metal: stainless steel
Pump impellors in thermal power stations are subject to
extreme wear through erosion, corrosion and abrasion .
Solution A.
Anti Wear Protection by SMAW(MMA) Welding:
Rebuild and protect wear sections with one of the following electrodes.
1) GOLD 330 special chrome nickel alloy electrode.
2) GOLD 320 special chrome, nickel manganese alloy.
Part: Impellor
Base metal: Cast-Iron
Problem:
Pump impellors in thermal power stations are subject to
extreme wear through erosion, corrosion and abrasion .
Solution
Anti Wear Protection by SMAW(MMA) Welding:
Rebuild and protect wear sections with one of the following electrodes.
1) GOLD 410 special pure nickel alloy electrode.
2) GOLD 420 ferro nickel alloy electrode
3) use CRC 5 cold weld compound if material is to Difficult to weld (Ni Hard etc.)
Base metal: Tin Bronze
Use GOLD 620 (ALMN Bronze) or 907 tin bronze
Tube bends
A) use thermal spray fuse process (gun 2010) and apply powder type 2060 SF (coat approx 1.5 mm thick)
TUBE PROTECTION
A) Use cold thermal spray process (UNISPRAY) and apply
Bond coat powder 2121 CS , followed by powder 2185CS
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BSW REPAIR APPLICATIONS
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BSW ANTI WEAR TECHNOLOGY
CONVEYOR SCREWS/AUGERS/WORMS/
EXTRUDRES
are subject to abrasion by coal, sand, cement, waste etc
causing the part to wear out and loosing feeding efficiency
ANTI WEARPROTECTION BY SMAW (STICK) WELDING
If screw shows heavy wear and needs rebuilding use one of the following electrodes.
1) GOLD 330/320 a universal electrode for rebuilding
2) GOLD 750/760 for hardfacing the wear aerea (flight, shaft)
GOLD 750 is a highly resistant chromium carbon alloy offering
maximum resistance to mineral abrasion.
New screws can be made from low alloy steel and then
Hard faced with Gold 750 (HRC 58) or Gold 760 (HRC 63)
This is a low cost and efficient procedure.
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BSW ANTI WEAR TECHNOLOGY