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7/30/2019 02 Welding Repair on Steel and Cast Iron
1/21
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
2/21
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
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.
7/30/2019 02 Welding Repair on Steel and Cast Iron
3/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
4/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
5/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
6/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
7/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
8/21
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
Electrode for repair Cast Iron
1. Pure Nickel Type electrode
2. Nickel-iron type electrode
3. Nickel-cupper type electrode
7/30/2019 02 Welding Repair on Steel and Cast Iron
9/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
10/21
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
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% )
7/30/2019 02 Welding Repair on Steel and Cast Iron
11/21
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
Sample of repair work
Crusher teeth Buffer layer E 307-16 , hardfacing E10-60 (OK84.78) %C 4.5 & Cr 33%, welding process SMAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
12/21
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
Re-Build Crusher Hummer (OK 15.65) DIN 8555 compositionC 0.9%, Si 0.4%, Mn13%, Ni 3% Welding Process FCAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
13/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
14/21
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
Hardfacing Teeth Exapator (OK 84.58) %C 0.7, Si 0.6%, Mn0.7% & Cr 10%, welding process SMAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
15/21
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
Hardfacing Tumbler (OK 84.84) %C 3.0, Si 2.0%, Cr 8.0%, V6.0% & Ti 6.0%, welding process SMAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
16/21
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
Repair Oil & Gas Drill Tools
Stabillizer drill tool, build up 304L powder andHardfacing Tungstent Carbide welding Process
PTAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
17/21
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
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
7/30/2019 02 Welding Repair on Steel and Cast Iron
18/21
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
Rail Repair
Mould Welding OK 74.74
7/30/2019 02 Welding Repair on Steel and Cast Iron
19/21
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
Tram Line Repair
Electrode AWS 5.4307-15 (OK 67.52)
Composition :
C 0.1%, Mn 6%, Cr18%, Ni 9%
Welding ProcessSMAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
20/21
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
Wheel Burn Repair
Filler OK Tubrodur 15.43
composition : C 0.15%, Cr1.0%, Ni 2.3% and Mo 0.5%
Welding Process FCAW
7/30/2019 02 Welding Repair on Steel and Cast Iron
21/21
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
THANK YOU