Worldwide repairs carried out with PolymerMetal - · PDF fileThe packing surface of an aluminium mould used for the production of foamed plastic ... with MM-metal SS-steelceramic and

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Worldwide repairs carried out with PolymerMetal®

REP-# 001

Repair of 14 bearing bushes of the gear box, which is destinated to the bucket wheel drive of an excavator for the field of open-cast mining. The worn bearing bushes with a diameter of 280 to 580 mm and a width of 130 to 150 mm were reconstructed with MM-metal SS-steelceramic and Hardener yellow. The standstill time of the excavator was considerable reduced to 72 hours.

MultiMetallthe MetalExistenceCompany™




REP-# 003

The packing surface of an aluminium mould used for the production of foamed plastic car seats was repaired by applying MM-metal SS-steelceramic. The thermal loading is 150 °C, the pressure 10 kg/m2.





REP-# 004

5 cracks in the casing of the water pump D-6300/80 at a land reclamation station was repaired with MM-metal SS-steelceramic and Hardener yellow.





REP-# 005

Repair of a marine engine with MM-metal SS-steelceramic and Hardener yellow. Damage: cracked packing surface between cooling water space and cylinder liner.





REP-# 009

Repair of a worn bearing seat on the drive of a bulldozer with MM-metal SS-steelceramic and Hardener yellow.





REP-# 010

Sealing of cracked leaky welding seams at crankcase of a ship diesel with MM-metal SS-steelceramic and Hardener yellow.





REP-# 011

Machining of MM-metal SS-steelceramic with diamond tools, i.e. Syndite PKD (trademark of „De Beers Diamond Division“). Data for maching: cutting speed vc = 60 - 125 m/min • cutting depth ap = 0,5 - 1 mm • feed f = 0,1 - 0,2 mm/U





REP-# 014

Corrosion damages at a brake drum caused by brake dust were repaired by using MM-metal SS-steelceramic and Hardener yellow.





REP-# 016

Repair of cracked Diesel injection pumps using MM-metal SS-steelceramic and Hardener yellow.





REP-# 017

Repair of a cracked valve casing by using MM-metal SS-steelceramic and Hardener yellow.





REP-# 019

A worn out bearing bush of a floating dredger was rebuilt using MM-metal SS-steelceramic and Hardener yellow. Besides MM-metal SS-steel liquid type with Hardener yellow liquid was injected into a gap of 4 mm between bearing bush and boom.





REP-# 020

Repair of a paper roll with a diameter appr. 600 mm, length appr. 3400 mm and weight 8000 kg. Cause of damage: undersize of up to 1 mm at one journal bearing of 270 mm diameter. The repair has been carried out with MM-metal SS-steelceramic and Hardener yellow. After curing the roll has been machined with diamond tools.





REP-# 021

Cracked welding seams in a silo tank were repaired by using MM-metal SS-steelceramic and Hardener yellow.





REP-# 022

Repair of a frost damage at a centrifugal pump. MM-metal SS-steelceramic together with Hardener yellow and MM-Fabric-tape (steel) has been used.





REP-# 023

Repairing of a car engine Mercedes Benz near the crankshaft by using MM-metal SS-steelceramic and Hardener yellow. For reinforcement a 1 mm steel plate with the outline of the hole was patched into the engine.





REP-# 025

Repair of four cracks on the cylinder block of a big engine called „Super MAZ“ were repaired with MM-metal SS-steelceramic and Hardener yellow. One of the cracks passed the oil channel and was therefore sealed with MM-metal oL-steelceramic and Hardener red.





REP-# 026

The packing surface of an adjustable propeller was repaired by using MM-metal SS-steelceramic.





REP-# 027

Repair of two tail bearings of a propeller shaft by using MM-metal SS-steelceramic, Hardener yellow and Hardener green. A ring with exact interior diameter has been bolted to both sides of the bearing. This ring has been centralized to the ideal shaft axis. Then MM-metal SS-steelceramic has been applied and been stretched parallel to the axis.





REP-# 028

Repair of a CV-plant´s double cross spray head for the manufacture of rubber-insulated cable with MM-metal SS-steelceramic and Hardener yellow.





REP-# 029

Repair of a grinding machine in a cement company. The damage, a worn out bearing housing, was repaired with MM-metal SS-steelceramic and Hardener yellow. Herewith the previous repair method „resurfacing by welding“ was replaced.





REP-# 030

Repair of a turbine casing using MM-metal SS-steelceramic and Hardener yellow. Operating conditions: pressure 4 bar, temperature 150 °C.





REP-# 031

A cylinder head of a car engine having corroded under water channels was repaired by applying MM-metal SS-steelceramic and Yellow hardener.





REP-# 032

Repairing of cylinder blocks and working faces of a big marine diesel engines with MM-metal SS-steelceramic. The repair was necessary due to damages caused by big abrasion between cylinder block and working face particularly in the region of the scaving air receiver. For this type of repair the engine manufacturer recommends to use exclusively MM-metal SS-steelceramic with Hardener green.





REP-# 034

Repair of a three-way valve housing for sea water. Material: grey cast iron. Damage: considerable wash-outs as well as a gaping hole in the valve housing. The repair was carried out with MM-metal SS-steelceramic and Hardener yellow and Ceramium, liquid with Hardener CE.





REP-# 036

The contact surfaces of a supercharger have been rebuilt with MM-metal SS-steelceramic and Hardener yellow.





REP-# 037

A cracked gearbox casing was repaired using MM-metal SS-steelceramic, Hardener yellow and MM-Fabric tape (metal).





REP-# 055

Repair of a worn-shaft-bearing for the adjustment of rolls at a 1200 ingot-blooms-rolling stand in a steel rolling mill with MM-metal SS-steelceramic. By the use of a PolymerMetal instead of a different repair method the down time was shortened from 75 to 19 hours. This is equivalent to appr. 7 working shifts. The use of the PolymerMetal MM-metal SS-steel 382, which has been developed in the meantime, would be recommended today, which offers even better compressive strength values for such types of repair. To this repair there is available an experience report upon request.





REP-# 062

The repair of a crack on the drying drum of a cotton spinning machine was carried out with MM-metal SS-steelceramic and Hardener yellow. Data: steam pressure 3 bar, steam temperature 180 - 240 °C.





REP-# 084

Repair of a turbo charger on board of a ship: during a voyage problems occurred at a turbo charger. The turbine inlet casing was removed and after cleaning a wasted area of appr. 600 mm x 130 mm on the lower part of the casing was revealed. Due to the technical possibilities on board the repair was carried out with MM-metal SS-steelceramic and a steel plate as reinforcement. At an exhaust temperature of appr. 400 °C in this repair area today MultiMetall’s VP 10-500 would have been the better choice.





REP-# 092

Sealing of 3 hydrogen pipings by using MM-metal SS-steelceramic. Hydrogen was escaping at 350 psi. A metal sleeve with a pressure compensating valve was prepared. MM-metal SS-steelceramic was applied on the sleeve and the pipings. While the valve was open the sleeve was assembled, therefore the hydrogen could easily escape through the opened valve. After totally curing of MM-metal SS-steelceramic the valve was closed and the installation was ready to operate. If the pipings had been exchanged the whole installation would have had to be stopped.





REP-# 111

Repair of a water pump. Damage: a crack of approx. 15 cm length. Data of the pump: year of construction 1969, power: 1500 m3/h, material: GGG-40.3, working pressure 20-40 bar. The pump has been repaired with MM-metal SS-steelceramic, Hardener yellow and MM-Fabric tape (carbon). Several attempts to carry out the repair by conventional welding before failed.





REP-# 118

Repair of the plunger of a metal bar extrusion press using MM-metal SS-steelceramic. The damage was caused by fatigue fracture. Length of the plunger 3800 mm, diameter 952 mm, weight 13 to., material: white cast iron, surface hardness 420 HB, hydraulic pressure 350 bar, operating pressure 2000 to. Procurement of a new plunger would have cost 81.000 EUR at a delivery time of appr. 9 months.





REP-# 119

Repair of the anti-wear blinding, carried out in a steel mill using MM-metal SS-steelceramic and Hardener yellow.





REP-# 122

Repair of a turbo charger using MM-metal SS-steelceramic. Today MultiMetall recommends the newer product VP 10-500.





REP-# 124

Repairing a corroded and worn out pillow block bedding of a steel sheet rolling line using MM-metal SS-steelceramic. The precise pillow block seat was obtained with the help of a metal plate.





REP-# 128

A carburettor has been repaired using MM-metal SS-steelceramic with Hardener yellow.





REP-# 130

A cracked housing of a hydraulic pump in a steering gear made off aluminium was repaired using MM-metal SS-steelceramic with Hardener yellow. Afterwards the whole housing was coated with VP 10-017 in order to seal the pores in the casting.





REP-# 134

34 damaged back-up rolls bearing houses of a steel work´s hot strip mill were modified. The above drawing shows a bearing shell which was damaged by turning of the outer bearing bore. Conventional repairs of these damages would have been executed by welding on, heat-treatening and turning to original size. Cheaper and less time intensive is an innovative repair with MM-metal steelceramic and Hardener yellow.





REP-# 135

34 damaged back-up rolls bearing houses of a steel work´s hot strip mill were modified. The above drawing shows guiding plates as a fixture to the bearing house. To achieve a constant distance to the bearing at unchanged plate thickness, the surface damaged by erosion and mechanical load was restored by MM-metal steelceramic and Hardener yellow.





REP-#153

Several cracks in cylinder no. 1 in the main engine block of a ship diesel engine, which probably occurred due to aging and vibration, have been closed with MM-metal SS-steelceramic and Hardener yellow. The cylinder jacket had long vertical cracks of 215 mm and 125 mm length and two further cracks of 135 mm each in the upper area. Even 7 years after the repair has been carried out, the repaired ship engine is in operation without complaints. The extreme difficult repair has been completed by our Netherlands partner company („EMHA technisch bureau b.v.“) and company Metalock in a port in Thailand.




Technical Report PolymerMetal®

TEC-# 007 The corrosion-chemical behaviour of PolymerMetals in combination with casting material (contact corrosion)

Used products MM-metal SS-steelceramic / MM-metal SQ / MM-metal SS-steel 382 / MM-metal SS-steel / MM-metal oL-steelceramic / MM-metal UW / Ceramium® / MM-metal S-steel

IntroductionPolymerMetals are used for repairs of metallic constructions which were damaged by physical loads like tear, impact, erosion, abrasion, corrosion and cavitation or by chemical load.

Questions of customers concerning the contact corrosion of our PolymerMetals lead us to do tests.

The following report shows how the test has been carried out and what results have been obtained. Tests have been made with seven different PolymerMetals in artificial sea water (laboratory test) as well as in aggressive marshy soil. The PolymerMetals used were potentially equivalent or potentially superior to the base material (cast iron).

Place of repair Moorland in the North of Germany and laboratory

Preparation of test samples 56 plates measuring 150 x 95 x 25 mm and 95 x 47 mm have been cut off cast iron. The surface of 23 plates has been treated mechanically. 2-3 bore holes of different diameters were installed in order to create different proportions between cast iron and PolymerMetals.

General information An ordinary salt spray test proved insufficient. As the tested PolymerMetals are non-electrical conductive products it was decided not to measure the current density potential curves. The contact resistance in the Meg-Ohm-sphere was too high.

Test in moorland Marshy soil is to be said very aggressive (DVGW rating no. -15 up to -19)

Reasons are: -very low soil resistance (appr. 950-1200 Ohm x cm) -very high salt content (chloride 800 - 1250 mg/kg / sulphate 4300 - 19000 mg/kg) -very high moisture contents (appr. 55 - 85%) -anaerobic conditions, proved by hydrogen-sulphide

The cast iron plates and PolymerMetals, machined and non-machined, were stored in a considerable depth of marshy soil for more than one year.

Test in artificial see water (laboratory test)The cast iron plates and PolymerMetals - machined and non-machined - were stored in a laboratory in considerable depth of artificial sea water (DIN 50 900) for more than one year.



SamplesThe following photographs show the different PolymerMetals applied to cast iron which have been partly machined after full curing. After they have been stored for 12 months in aggressive moorland or artificial sea water the samples have been examined. The following four photographs concern machined samples which have been exposed to artificial sea water:

Sample MM-metal SS-steelceramic Sample MM-metal SS-steel

Sample MM-metal oL-steelceramic Sample MM-metal UW

ResultThe results of both tests were nearly the same. Due to the strong reaction caused by the aggressive soil or by the sea water the cast iron plates were coated with ferric hydroxide. While the surface of the cast iron plates were differently affected, the PolymerMetals still remained unchanged after storage of more than 12 months. They were only covered with rust deposit. Even peak-to-valley heights from previous treatments could clearly be recognised. There was no contact corrosion, not even at the transitional point of the PolymerMetal and the cast iron. It was proved that PolymerMetals are not electrically conductive and cannot constitute any local element with cast iron.

Tested PolymerMetals MM-metal SS-steelceramic MM-metal SS-steel 382 MM-metal SS-steel MM-metal SQ MM-metal oL-steelceramic MM-metal UW Ceramium®

MM-metal S-steel





TEC-# 008 Repair of a shaft with PolymerMetals

Used products MM-metal SS-steelceramic / MM-metal SS-steel 382 / MM-metal SS-steel / MM-metal SS-aluminium / MM-metal SS-copper / MM-metal SS-bronze / Ceramium® / Molymetall®

IntroductionThe high quality PolymerMetals from MultiMetall can be used to repair worn shafts by restoring material. This report is supposed to assist the applicator during the repair. Because of the different sizes of wear length areas and diameters of the shaft to be repaired and the available processing time of the PolymerMetals (pot life appr. 30-35 min at 20 °C) the application of the PolymerMetals was divided into four variants.

Preparation• shaft has to be turned off in the area of the damaged part to at least 1 mm undersize from target diameter, the surface quality should be appr. Rz 100 afterwards • clean shaft from oil, grease, coolant etc with MM-Degreaser Z or MM-Degreaser C • adhere to Technical data sheet of used PolymerMetal especially consider the available processing time (pot life)

Application of PolymerMetal Variant 1: Shaft length of wear area < 150 mm and diameter < 200 mm• Shaft hold by lathe has to run with a low turning speed during all following repair steps • Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the

complete wear area of the shaft to avoid air bubbles in the interface between metal and PolymerMetal

• Apply PolymerMetal on complete wear length of shaft in a layer of appr. 2 mm oversize against target diameter

• By using a metal rule which is long enough (and therefore reaching over the complete wear length) the surface of the PolymerMetal should be smoothened so that an oversize of only 1-2 mm remains



Variant 2: Shaft length of wear area < 150 mm and diameter > 200 mm• Shaft hold by lathe has to be turned by hand during all following repair steps • Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first

part of the wear area („1“ on sketch) of the shaft to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter

• Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the second part of the wear area („2“ on sketch) of the shaft to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter

• Go on applying PolymerMetal in the same way on all other parts of the wear area till the complete wear area is coated

• If possibly there is enough pot life, use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains

• Hint: the transitions shown in the sketch i.e. between part area 1 and part area 2 are fluid and do not have to be kept strictly



Variant 3: Shaft length of wear area > 150 mm and diameter < 200 mm• Shaft hold by lathe has to run with a low turning speed during all following repair steps • Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first

part of the wear area on the length of appr. 150 mm on the complete shaft perimeter to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter; use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains

• Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the second part of the wear area on the length of appr. 150 mm on the complete shaft perimeter; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter; use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains

• Go on applying PolymerMetal in the same way on all other parts and smoothen the surface of the PolymerMetal till the complete wear area is coated and pulled

Variant 4: Shaft length of wear area > 150 mm and diameter > 200 mm• Shaft hold by lathe has to be turned by hand during all following repair steps • Divide the shaft into several max appr. 150 mm long areas • Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first

shaft section of the wear area („A“ on sketch) on the length of appr. 150 mm of the first part of the wear area to avoid air bubbles in the interface between metal and PolymerMetal; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter

• Apply a thin layer (max 0,5 mm) of PolymerMetal with a spatula with pressure on the first shaft section of the wear area („A“ on sketch) on the length of appr. 150 mm of the second part of the wear area; then apply PolymerMetal on the same part of the wear area in oversize of appr. 2 mm against the target diameter

• Go on applying PolymerMetal in the same way on all other shaft sections and parts till the complete wear area is coated

• If possibly there is enough pot life, use a metal rule which is long enough (and therefore reaching over the complete wear length) to smoothen the surface of the PolymerMetal so that an oversize of only 1-2 mm remains



Further processing• Wait till PolymerMetal has been totally cured (adhere to Technical data sheet) • Further processing of the shaft without cooling/greasing agent • Depending on used PolymerMetal machine the coated surface with Diamond or standard

tools

Material MM-metal SS-steel 382 MM-metal SS-steel

MM-metal SS-aluminium MM-metal SS-copper MM-metal SS-bronze

each with Hardener yellow

Molymetall®with Hardener Molymetall®

MM-metalSS-steelceramic

with Hardener yellow

Ceramium®

with Hardener CE

Type of machining standard tools diamond toolsGeneral machining dataCutting speed vcCutting depth apFeed f

40...55 m/min 0,5...1 mm

0,1...0,2 mm/U

60...125 m/min 0,5...1 mm

0,1...0,2 mm/U Recommended machining data at rough turning Cutting speed vcCutting depth apFeed f

80 m/min 2 mm

0,125 mm/U Recommended machining data at finish turning Cutting speed vcCutting depth apFeed f

125 m/min 0,5 mm

0,125 mm/U * For machining we recommend to use Syndite (trademark of the „De Beers Industrial Diamond Division“) PKD tools grade 010 respectively 025. After machining with PKD tools the surface quality of the coating has a medium peak-to-valley value of Ra 3,4 µm.





TEC-# 013 Wear tests

Used products MM-metal SS-steelceramic / Ceramium / Ceramium DW

Dry wear test

50

145

70

400

0

50

100

150

200

250

300

350

400

450

linear amount of wear

Ceramium

MM-metal SS-steelceramictool steel HRC 65construction steel St 37

The type of wear phenomena occurring at the tests corresponds with the sliding abrasion (three body abrasion) according to DIN 50320.

Wet wear test

6575 80

160

0

20

40

60

80

100

120

140

160

180

volume wear in mm3

CeramiumCeramium DWtool steel HV 840construction steel St 52

The type of wear phenomena occurring at the tests corresponds with the particle erosion (erosion water) according to DIN 50320.





TEC-# 020 Repair of a propeller shaft with PolymerMetals (short version)

Used products MM-metal SS-steelceramic / MM-metal SS-steel 382 / MM-metal SS-steel/aluminium/copper/bronze / Ceramium / Molymetall

DescriptionPolymerMetals can be used to repair worn shafts by restoring material. Here the PolymerMetal can be applied during running shaft followed by turning down to nominal diameter. For this repair should be used one of the above mentioned PolymerMetals. Further information concerning the repair of a shaft with PolymerMetals can be found in the „Technical Report TEC-# 008“.





TEC-# 029 Pressure tight test at low temperatures

Used products MM-metal SS-steelceramic

Testing method: It was tested the pressure tightness of a repaired leakage at a test cylinder according to above drawing. For this MM-metal SS-steelceramic with Hardener yellow has been applied to the dry metal surface. After full curing of 24 h at 21 °C the test cylinder was filled with a liquid (here: oil-water-mixture). Then the test cylinder was cooled down inclusive contained liquid to minus 35 °C and a pressure of 200 bar was built up in the system. This temperature and pressure was kept constant over a testing period of 50 h. This test was carried out concerning special repair demands of a customer (permanent pressure of 200 bar at a very low temperature of minus 35 °C).

Results / conclusion: Although low temperature and high pressure are effective at the same time, there has not been measured any pressure reduction in the system after expiration of the test period. MM-metal SS-steelceramic in combination with Hardener yellow is a high-quality repair material, which withstands high permanent pressures even at very low temperatures.


MM-metall SS-StahlKeramik MM-metal SS-steelceramic

Documents

Worldwide repairs carried out with PolymerMetal - · PDF fileThe packing surface of an aluminium mould used for the production of foamed plastic ... with MM-metal SS-steelceramic and