Fidur Wear Protection - Kjellberg Finsterwalde

Extremely Tough
With Fidur Wear Protection
Welding Systems, Surface-Welded Sheets,
Filler Materials and Coating Service
www.kjellberg.de

Surface Welding Processes
Technology
Surface welding, also called cladding,
means that work-pieces receive a wear-resistant
extra layer, a so-called hard surfacing.
This is done for repair purposes or to
create material compounds with specific
functions. The lower the dilution rate of the
surfacing, taking into account the necessary
adhesion, the higher the quality of the
layer’s properties. For surface welding,
processes like GMAW, TIG welding, submerged-arc
welding and plasma welding,
are used.
Surface welding
Fields of Application
Surface welding is used as effective protection
in particular against abrasive and erosive
wear on machinery and components in
mining, ore dressing, the cement and coal
industry and in road construction. By applying
a strongly adhesive layer, surfaces
are repaired, armoured for wear protection
purposes, cladded for corrosion protection
purposes and buffered for intermediate
layers.
Wear protection in the industry
• Coal and brown coal power stations
• Cement plants
• Steel industry
• Mining
• Deep drilling industry
• Foundries
• Tunnel driving
• Mineral extraction and mineral processing
A typical example: From coal extraction in mining to coal
refinement in power stations, FIDUR made by Kjellberg
Finsterwalde offers optimum wear protection along the entire
value chain.
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Stationary, Flexible and Mobile Systems
Systems for Surface Welding
Do you want to produce your own surface-welded
sheets? For this purpose, Kjellberg
Finsterwalde offers suitable surface
welding systems as complete solution:
stationary, with flexible robot technique or
as mobile plant.
Stationary gantry for surface welding of standard sheets
Application advantages
• Process reliability due to stored parameter
sets and welding data collection
• High level of plant availability due to automatic
operation
• remote diagnosis via internet access
possible
System components
• Gantry as stable steel construction
• Welding power sources
• Welding heads
• Central control panel for adjustment of
welding parameters
• Switching cabinet, etc.
Flexible robot welding station for welding of claddings
Depending on the type of surface welding,
the local conditions and other parameters,
we construct and produce together with
you a plant that fits your requirements
exactly – no matter what size or specific
features.
We also recommend our training
courses on surface welding to achieve
optimum results with our welding
gantries.
The mobile welding system is set up for welding on your
site and removed afterwards.

Surface-Welded Sheets
Standard Sheets
Surface-welded sheets are a cost-efficient
solution for large-area wear protection
purposes. They are composed of a weldable
base sheet that is covered with a hard
surfacing.
Surface-welded standard sheet of the type Fidur 10/65 P
Materials of the base sheet
All weldable steels, e.g. S235, S355,
QSTE 690, 1.4301, 1.4828
Materials for hard surfacing
Chromium carbides in martensitic/austenitic
matrix
For the production of hard surface layers,
special welding methods are used. They
guarantee an even wear resistance across
the entire thickness of the hard surfacing.
Due to the metallurgical bond between the
hard surfacing and the base sheet, flaking
is avoided.
Surface-welded sheets can be cut with
plasma, deformed and, if specific regulations
are met, welded.
Qualities
Sheets
Composition of
the weld metal
Fidur
10/65 P
5 % C,
30 % Cr
Fidur
10/65V P
5 % C,
22 % Cr,
7 % Nb
Fidur
10/65W P
5 % C,
22 % Cr,
7 % Nb,
7 % Mo,
V, W
Hardness 60 HRC 62 HRC 65 HRC
Max operating
temperature
350 °C 350 °C 700 °C
Structure of type Fidur 10/65 P: primary chromium carbine
with in martensitic austentic matrix
For applications, where caking of the conveyed
material should be avoided or where
the sliding properties of the conveyed material
should be improved, it is possible to
deliver surface-welded sheets with particularly
smooth surfaces.
For the further processing of hard surfaced
sheets by plasma cutting and/or welding,
products from Kjellberg Finsterwalde are
optimally suited.
Dimensions
Length 2,000 mm 2,500 mm 3,000 mm
Width 1,000 mm 1,250 mm 1,500 mm
Thickness
(base material
+ layer)
4 + 2 mm
5 + 3 mm
6 + 4 mm
8 + 5 mm
8 + 10 mm
8 + 12 mm
5 + 3 mm
6 + 4 mm
8 + 5 mm
8 + 10 mm
8 + 12 mm
6 + 4 mm
8 + 5 mm
8 + 10 mm
8 + 12 mm
Special qualities and dimensions are
available on request.
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Surface-Welded Sheets
Special Sheets
Plasma cuts to size and ready-to-install
constructions
The plasma cuts to size are made of surface-welded
standard sheets. The cutting
to size is done with plasma technique from
Kjellberg Finsterwalde.
Plasma cuts to size
Surface-welded plasma cuts to size for the lignite industry
Max length
Max width
Min hole diameter
Max sheet thickness
6.000 mm
2.000 mm
6 mm
8 + 12 mm
Ready-to-install constructions are made of
surface-welded standard sheets or pre-assembled
parts are coated afterwards with
the help of modern robot technique.
The existing welding and cutting technologies
in combination with deformation
and subsequent mechanical processing
methods make it possible to manufacture
constructions from surface-welded sheets.
These are cost-efficient due to cutting
waste optimization on the one hand and
feature high quality and fitting accuracy on
the other hand.
Our systems are designed with CAD. With
this program it is possible to open and use
files of all common programs (Autocad,
Catia, etc.).
Surface-welded components for the steel industry
Parts with surfacings
Parts
Pipes, pipe
elbows (inner
layer)
Min diameter 200 mm — —
Containers,
cyclones,
other constructions
Mechanically
processed
parts
(turning,
milling)
Max diameter
— 2,500 mm 1,500 mm
Max length — 4,000 mm 4,000 mm
Max width — 2,500 mm —
Max part
weight
5,000 kg 5,000 kg 2,500 kg
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Filler Materials
Welding Electrodes
Filler materials for hard surfacing are used
to apply wear protection layers on existing
parts later on or to regenerate worn parts.
Electrode qualities
Fidur electrodes are suitable for surfacings that are exposed
to extreme abrasion and high temperatures.
Electrode
Composition of
the weld metal
Fidur
10/65
5 % C,
30 % Cr
Fidur
10/65V
5 % C,
22 % Cr,
7 % Nb
Fidur
10/65W
5 % C,
22 % Cr,
7 % Nb,
7 % Mo,
V, W
Hardness 60 HRC 62 HRC 65 HRC
Max operating
temperature
350 °C 350 °C 700 °C
Electrode dimensions
Diameter
Packaging
3.2 mm, 4 mm, 5 mm
5 kg, 6 kg (Cardboard
box)
Flux Cored Wire
For the processing of filler materials, Kjellberg
Finsterwalde’s welding technique can
be used optimally (welding power sources,
wire feeding units, welding torches, welding
gantries).
Flux cored wire qualities
Fidur flux cored wires are optimally suited for surfacings on
stationary plants.
Flux cored wire
Composition of
the weld metal
Fidur
10/65 FD
5 % C,
30 % Cr
Fidur
10/65V FD
5 % C,
22 % Cr,
7 % Nb
Fidur
10/65W FD
5 % C,
22 % Cr,
7 % Nb,
7 % Mo,
V, W
Hardness 60 HRC 62 HRC 65 HRC
Max operating
temperature
350 °C 350 °C 700 °C
Special qualities and dimensions are
developed individually according to
your requirements.
Flux cored wire dimensions
Diameter
1.6 mm,
2.4 mm
2.8 mm,
3.2 mm
Abpackung
15 kg mandrelmounting
reel
25 kg basket
coil
250 kg cask
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Coating Service
We Take our Time for You
Let us refurbish your worn parts and save
the costs for new purchases. Furthermore,
you can reduce the downtimes of production
plants and thus increase your productivity.
For every request there is the right solution. We will find it
together with you.
With the coating service Kjellberg Finsterwalde
offers the optimum solution in our
own workshops as well as on your site. We
use customized welding plants and suitable
filler materials and have professional expertise
to regenerate parts with high-quality
wear protection – we are flexible, on time
and act worldwide.
Application Examples
Regeneration of a grinding roll
Cost-efficient refurbishment of grinding roll
with Kjellberg flux cored wires which at the
same time increase the lifetime due to the
high wear resistance of Fidur 65/10 FD
Regeneration of a coal mill on site
On-site regeneration of grinding tables
and grinding rolls for coal and cement mills
with high efficiency thanks to mobile welding
systems in combination with high-performance
flux cored wires
Worn grinding roll before regeneration
On-site regeneration of grinding tables and grinding rolls
You can also use our rental service.
For more information please read the
back side.
Regenerated grinding roll
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All-Round Wear Protection
Using synergies and saving costs –
all products for surface welding along
the entire process chain are available
from Kjellberg Finsterwalde.
• Surface welding with Kjellberg surface
welding plants and surface welding materials
• Plasma cutting of surface-welded sheets
with the most modern Kjellberg plasma
cutting technique
• Local armouring afterwards and joint
welding on parts with welding power
sources (e.g. Tiny 250 Cel) and welding
filler materials from Kjellberg
Finsterwalde
Expertise for all Requirements
Advisor and Full-Range Supplier
Planning and construction
Sheet cutting to size
Our product portfolio
• GMA welding technique
• PTA welding and plasma keyhole welding
• Thermal spraying
• Submerged-arc welding technique
• Special welding method InFocus
• Peripheral welding equipment
• Complex systems
• Filler materials, accessories, options
Rolling and deforming
Welding
Renting as alternative
With our rental service maintenance gaps
and production peaks are no longer a problem.
Of course we offer specialized advice
and delivery as well as detailed introduction
and collection after the work is done.
Colouring
Assembly and installation
Kjellberg Finsterwalde Group
Welding Electrodes
Welding Equipment
Cutting Equipment
Mechanical Engineering
Our products represent a high level of qualitiy and reliability.
Claims of any kind can not be derived from this brochure.
Copyright © 2013 Kjellberg Finsterwalde
Schweißtechnik und Verschleißschutzsysteme GmbH
All rights reserved.
Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH
Stockumer Str. 28 | DE-58453 Witten | Phone/Fax: +49 2302 2025-940 /-945 || Oscar-Kjellberg-Straße 18 | DE-03238 Finsterwalde | Phone/Fax: +49 3531 500-319/-357
www.kjellberg.de | schweissen@kjellberg.de
13-03-02