Repair & Maintenance Repair & Maintenance - Esab

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A welding review published by ESAB AB, Sweden No. 1, 2001 Articles in Svetsaren may be reproduced without permission but with an acknowledgement to ESAB. Publisher Bertil Pekkari Editor Lennart Lundberg Editorial committee Klas Weman, Lars-Göran Eriksson, Johnny Sundin, Johan Elvander, Sten Wallin, Bob Bitzky, Stan Ferree, Ben Altemühl, Manfred Funccius, Dave Meyer Address ESAB AB, Box 8004, SE-402 77 Göteborg, Sweden Internet address http://www.esab.com E-mail: info@esab.se Printed in Sweden by Geson Skandiatryckeriet, Kungsbacka Repair & Maintenance. Contents Vol. 56 No. 1 2001 3 The repair of aluminium structures Some of the more common considerations associated with the repair of aluminium alloys. 17 Submerged-arc strip cladding of continuous casting rollers using OK Band 11.82 and OK Flux 10.07 Surface welding of continuous casting rollers with submerged arc welding is preferred because of its higher deposition rate compared to MAG welding. 6 Advanced production technology leads to time savings of 25 % Large pistons for diesel engines are refurbished by welding rather than putting a totally new piston into service. 20 ESAB delivers engineered automatic welding station to Ghana in Africa for build-up welding of worn railway wheels Re-building of worn parts of wheel surfaces by welding is an effective method. 8 Corrosion- and wear-resistant 17% Cr strip weld overlays The strip weld-overlay technique used for renovating of parts in the machinery manufacturing industry increases productivity and reduces the likelihood of defects. 22 Cobalarc: The future of manual hardfacing Electrodes mainly used for hardfacing in applications where the prime factor of wear is abrasion. 11 ESAB: your digital partner for welding and cutting A guide to the 21 ESAB websites 25 Repair welding of blades for rubber mixing Re-building of the mixing equipment used for manufacturing tyres for vehicles. 13 Stubends & Spatter Short news 2 • Svetsaren nr 1 • 2001
The repair of aluminium structures by Tony Anderson, Technical Services Manager AlcoTec Corporation, USA Without a doubt, aluminum is being increasingly used within the welding fabrication industry. We are seeing a major increase in usage within the automotive industry, where the use of aluminum continues to develop. Also within other industries such as furniture, recreation and sporting equipment, shipbuilding, transportation and containers, military and aerospace we see continued developments with aluminum, often as a replacement for steel. As more components are produced from aluminum, the need for reliable repair work on aluminum weldments is also increasing. Repair work to aluminum structures is conducted extremely successfully on a regular basis, such items as truck body’s and boat hulls are repaired after damage from collision or after wear and tear during severe service conditions. This article shall examine some of the more common considerations associated with the repair of aluminum alloys in an attempt to help prevent problems associated with repair work and also to help ensure consistently successful repairs. Identification of alloy type Probably the most important consideration encountered during the repair operation is the identification of the aluminum base alloy type. If the base material type of the component requiring the repair is not available through a reliable source, it can be difficult to select a suitable welding procedure. There are some guides as to the most probable type of aluminum used in different applications, such as, most extruded aluminum is typically 6xxx series (AL-Mg-Si). Air-conditioning systems and heat exchangers, within the automotive industry, are typically made from 3003, 5052, plate and 6061 tubing. Car wheels are often made from 5454, which because of its controlled magnesium (less than 3% Mg), is suitable for temperature applications. Ship hulls are often manufactured from 5083 (5%Mg), which is recognized as a marine material. Unfortunately, if the base material type is not known, or unavailable, there is only one reliable way of establishing the exact type of aluminum alloy, and that is through chemical analysis. A small sample of the base material must be sent to a reliable aluminum testing laboratory, and a chemical analysis must be performed. Generally, the chemistry can then be evaluated and a determination as to the The most important consideration before repair welding is the identifcation of aluminum base alloy type. most suitable filler alloy and welding procedure can be made. It is very important to be aware that incorrect assumptions as to the chemistry of an aluminum alloy can result in very serious effects on the welding results. There are 7 major types of aluminum alloys which have a wide range of mechanical properties and, consequently, a wide range of performance and applications. Some have very good weldability, and others are considered to have extremely poor weldability, and are unsuitable, if welded, for structural applications. Some can be welded with one type of filler alloy, and others will produce unacceptable, Svetsaren nr 1 • 2001 • 3
Page 1: A WELDING REVIEW PUBLISHED BY ESAB
Page 5 and 6: Base material strength reduction af
Page 7 and 8: which leads to a higher melting rat
Page 9 and 10: Figure 2. Hydraulic piston Designat
Page 11 and 12: ESAB: your digital partner for weld
Page 13 and 14: Stubends & Spatter Railtrac was the
Page 15 and 16: The most sophisticated panel cuttin
Page 17 and 18: Submerged-arc strip cladding of con
Page 19 and 20: Nickel % 5,0 4,0 3,0 2,0 1,0 0,0 3,
Page 21 and 22: Welding and hardness Wheel Consumab
Page 23 and 24: component does not have any metallu
Page 25 and 26: Repair welding of blades for rubber
Page 27 and 28: ✂ Order form ■ Please register

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