Hypertherm: Life Expectancy of Consumables

Cutting Scenarios:

Blog Archives - Welding Alloys Manufacturers In India

Hypertherm: Life Expectancy of Consumables

It’s hard to offer an exact (or even an in-exact) estimate of the number of factors that impact the life expectancy of a plasma cutter consumable —operator experience, type and age of the torch, material type and thickness, air quality, etc. However, when the operator understands good piercing and edge-starting techniques which keep molten metal from blowing back onto the torch nozzle (or tip if it is a non-Hypertherm system) then the life of the consumable can be extremely long. Hence, Hypertherm plasma cutter consumables have an edge over conventional plasma cutting machines.

Hypertherm Life Expectancy of Consumables

Cutting Scenarios:

The biggest problem with most plasma cutter torches occurs when hand cutting with exposed (unshielded) nozzle-torch consumables. Ideally, you need to hold a standoff, with an unshielded setup at all amperages greater than 30 amps or so. If the nozzle touches the plate during a cut, it creates an electric current path between the negative electrode, nozzle, and positive plate. This causes a double arc between the electrode and nozzle, and the nozzle and plate, which damages the nozzle’s orifice. When the orifice gets a little damaged, poor angularity is the first thing you’ll notice, followed by more double arcs and more damage. Eventually, you’ll notice slower cut speeds and heavy dross, at which point you’ll likely change your nozzle.

Secondly, some people use a standoff device to hold the torch up off the metal. Unfortunately, molten metal can still blowback during piercing, once again passing electricity from the nozzle to the plate and leading to double arcing. If you have used a handheld torch with an exposed nozzle at more than 30 amps while drag cutting, you’ve likely felt the torch “sticking” to the plate. This is a result of double arcing.

Hypertherm Patented Solutions for Longer Life:

One way around this problem is through the use of shielded torch technology, invented and patented by Hypertherm in the ’80s. The shield works to electrically isolate the nozzle from the plate to totally eliminate double arcing. Hypertherm plasma shielded torches drag cut at up to 200 amps with no friction or double arcing for a dramatic improvement in a plasma cutter consumable’s life and cut quality.

In the last 30 or so years since Hypertherm introduced shielded torch technology, engineers have made enormous strides in extending the life of these consumables. For example, our Duramax torches of Hypertherm plasma systems come with the new standard consumables with nearly all new Powermax systems and as a retrofit torch for older Hypertherm systems and use the shield for just nozzle isolation. The shield and nozzle for these torches use a patented technology called Conical Flow to inject greater airflow around the perimeter of the arc. This increases the energy density of the arc and provides better cooling to the nozzle. This results in no sticking, no double arcing, offering faster-cut speeds, thicker piercing capability, and dramatically longer nozzle life.

So, assuming you are using a Hypertherm plasma Duramax torch with the latest consumable technology, then I would expect you to cut hundreds of feet of metal. In addition, you should be able to make between 600 and 1,200 pieces, after which you would need to replace only your electrode. All your remaining Hypertherm consumables would likely continue to work just fine. Put another way, you should be able to get between 2 and 4 full days of actual arc-on time before needing to replace any of your consumables.

This is why Ador Fontech Limited, the name synonymous with total solutions for any Maintenance & Repair solutions, recommends Hypertherm plasma with Duramax Torch and consumables as a robust cutting solution to all our customers. “Using Spurious/Counterfeit consumables is nothing but a shortcut to machine breakdown & loss of warranty.”

Corrosion and Cracks in Kiln Shells – Repair Solutions from ADFL

Cement Industry uses Rotary Kiln for Pyro-processing the raw mixture of finely crushed limestone (calcium carbonate + silica-bearing minerals) to manufacture cement. Kiln or kiln shell is at the heart of the cement-making process; its capacity, usually defines the capacity of the cement plant.

The Rotary Kiln consists of a tube made up of structural rolled steel material and lined with firebrick (or) castables. This kiln shell/tube slopes (1⁰to 4⁰) from one end to another, and slowly rotates on its axis at between 30 & 250 revolutions per hour depending on the plant. Raw mix is fed in the upper end and the rotation of the kiln causes the mix to move gradually to the other end of the kiln shell. At the other end to the lower part of the kiln, the burner pipe system provides a concentric flame. The raw mix moves under the flame and reaches its peak temperature before it drops out of the kiln into the cooler. In principle, the air drawn through the cooler flows into the kiln causing combustion of the fuel fed through burner pipe ensuring intense heat right across the kiln shell taking the temperature close to 1450⁰ C turning the raw mix into fully calcinated clinker.

Corrosion and Cracks in Kiln Shells

This Kiln shell made of structural rolled steel has a tensile strength between 50,000 to 80,000 PSI at room temperature but once it goes beyond 200 degrees. The tensile strength drops rapidly and at around 430 degrees, studies have noted a strength loss of close to 50% from its original strength.  Because of its continuous working condition at this high temperature along with corrosion caused by castables (which also cause thickness reduction in Rotary kiln or Kiln shell). After a period, fatigue develops in the kiln shell lining and with any small damage to the firebrick or castable it has a temperature attack or thermal shock in the kiln shell causing hot spots and red spots leading to cracks.

Hot Spot & Red Spot

Hot spot is an isolated area in the Rotary kiln where the Kiln shell temperature is close to 550 deg. It is not visible to to the naked eye but can be deducted by Shell scanner, also known as portable Infra-red pyrometer. Red spot is an area visible at night, indicating that the temperature is above 550 degrees. In layman’s terms, hot spot is like a warning sign that action is needed but red spot means immediate action with stoppage of Rotary kiln. Every hot spot eventually becomes a red spot-causing cracks in kiln shell. With today’s improved technology the shell temperature is monitored continuously with computer-aided sensors.  At times kiln is stopped on deduction of a hot spot on further inspection cracks are noticed in the Kiln shell for immediate action

Generally, cracks that are perpendicular to rotary kiln and not of significant lengths and depth are repaired by welding. If the cracks are circumferential in nature, the particular portion is cut and removed & a new shell of the same length is inserted, aligned & welded. Also, kiln shell replacement is the preferred method in most cases of the red spot.

ADFL holds pre-eminence in both these types of repair – kiln shell repairs & kiln shell replacement. Further, we also offer a wear protection solution for high-temperature corrosion

  • We offer customized solutions for the repair of rotary kiln shell cracks with a combination of our LH 1105 & LH 521 alloys. We have credentials in attending a number of these kinds of breakdowns shutdowns
  • We are the only solution provider to offer automated kiln shell joining using the SAW process for kiln shell replacement jobs. By using an automated SAW process, we can complete a single joint in 24-36 hours – offering the highest productivity with X-ray quality welding
  • We also supply kiln shells & cowl shells of the required dimensions. This is a fabricated shell with single SAW joints, making it a value proposition to the industry.
  • We also have a Wear Protection solution for Rotary Kilns against high-temperature corrosion, Zircoat-M, a high-temperature coating, can be applied to a kiln shell’s inside portion before fixing castables to totally eliminate corrosion problems in kilns.

With such customized solutions for any maintenance, repair, and refurbishment requirements, Ador Fontech Limited remains the first name to recall for customers across India, as we stay true to our motto of Life Enhancement of industrial components in every sphere possible.

Reclaim, Do not Replace

Resolve the Challenges in M&R Welding with Unique Electrodes

To understand the types of Welding Electrodes, more commonly known as welding rods in welders parlance, it is essential to understand the particular type of application it is used for a specific industry. Welding is, primarily needed to fabricate new parts or components. Secondly, it is used to repair broken/cracked components or to hard-face and build up a worn-out component to prolong its life. Hence it is essential to classify welding by these two types of applications.

  • Electrodes for Fabrication Welding
  • Electrodes for Maintenance & Repair Welding

Resolve the Challenges in M&R Welding with Unique Electrodes

What is the difference?

Specifications of welding electrodes (or) rods used in the production or fabrication of components are largely confined to meeting the minimum requirements of a particular class. Basically, conventional electrodes are designed essentially for production welding. In other words, they are expected to meet the specifications and design parameters of a specific component. Based on such an evaluation, a welding engineer chooses a particular electrode, only when it meets his requirements.

But in the case of Maintenance & Repair (M&R) welding, these specifications are too broad to realistically meet the precise & varied requirements of a repair application. Hence M&R products are basically Low Heat (LH) input welding rods or electrodes. They are designed to weld specific components to give them extended life or improve their performance. In most cases of M&R, we use a welding electrode to repair a broken component or worn-out component. In the process, we always go beyond the original design parameters to ensure that the refurbished component has the best properties & optimal performance.

Resolve the Challenges in M&R Welding with Unique Electrodes

Key Differences to Consider:

  • Composition of Base Material – In the case of fabrication welding, the job is carried out on new & known components, so all parameters are known. We can choose the welding material exactly, knowing the composition of the base material. This makes it easy to select the right welding electrode for the job. But in the case of Maintenance & Repair, the welding job is done without knowing the exact base material. This makes it necessary for us to have access to versatile products, which can be welded onto different types of base materials, like steel, cast iron, etc.
  • State of Welding Component: In the case of fabrication welding, the job is done using pristine new plates. So, there are no special requirements while in the case of M&R welding, most of the welding needs to be done with fatigued, old, and contaminated components. Such welding jobs call for welding electrodes with richer chemistry & properties to match this specific requirement.
  • Preparation of Joint: In fabrication welding, all welding parameters are clear, so welders just need to adhere to them to complete a job properly. In the case of M&R welding, the job is many times conducted in-situ or at the site. This requirement complicates the task, as we will not be in a position to make any provision to prepare the area to be welded, like a V groove, which is ideal to ensure a proper job. Under such circumstances, the rich alloying elements of the welding electrode need to offer additional strength to the joint.
  • Type of Welding: Usually, any fabrication facility or workshop insists on executing a welding job using a flat or down-hand welding position only, as this is considered to be the best position to achieve ideal welding standards. But ensuring a down-hand welding position is not always possible with M&R welding because the work is mostly done on-site, and we may not always have the choice of position. This is why all M&R electrodes of Ador Fontech make are designed to enable welding from any position, making them unique.
  • Extended Work-Life: Extending the work-life of the original component is very important, in both types of welding as customers are more worried about the reliability and life extension offered by a repair. This is understandable as no plant can accept stoppages or breakdowns, especially after undertaking extensive repairs to fix all issues. M&R Electrodes/Rods offer an ideal solution in cases where we want to design products or components with extended life.
  • Special Re-Enforcement: When we are fabricating a component, it is always done as per a product’s design & drawing, so no special re-enforcement will be required. But in the case of M&R welding, we will be required to apply special re-enforcement techniques to ensure a long life for the repaired component.
  • Deadline for Completion: In fabrication welding, there is always a deadline set for completion, but it is always under control as this will be a planned activity. But most M&R welding jobs happen when there is a breakdown or stoppage. So, we need special products which can weld without pre or post-weld heat treatment so the job gets completed faster with the highest level of reliability.

Focusing on all the above considerations, Ador Fontech has designed & developed an exclusive Range of LH –Low heat Input Welding Electrodes/rods(Alloys) to resolve the specific problems in Maintenance & Repair welding.

Reclaim, Do not Replace

Refurbishment of Impact Crusher –The Ador Way

Process industry generally requires the mineral ore’s needs to be processed. In other words, it needs to be crushed into a near powder form from its natural state. Typically, if you take an example from the cement industry, limestone extracted from mines is crushed close to a powder form before it moves on for further processing in grinding mills and then fed into a kiln from the cement-making process. The mines where the crushers are located form the backbone of the industry, making it a vital area for refurbishment as wear rates are very high due to high abrasion & impact caused by abrasive materials.

The most widely used and most efficient crusher machinery system for this task is the Hydraulic Impact crusher.  Nowadays this is predominantly used in Cement Industry as this simplifies crushing by doing the work of both primary & secondary crushers earlier used in the industry. The working process is very simple. Limestone ore is fed into the horizontal Impact Crusher inlet as it falls into the rotating rotor.  then it gets crushed by the blow bar, inside the impact crusher during the crushing process, the front impact arm ensures the compressive loading of the ore. The rear impactor Arm & Grinding path ensures the fine crushing of limestone for further processing.

View of Horizontal Impact Crusher:

Refurbishment of Impact Crusher

The main wear factors acting on the component are High Abrasion & Impact with compressive loading inside the Horizontal Impact Crusher. The main components r get worn out are the Front & Rear Impact arms or Impactor arms, grinding path, blow bars, and the rotor body. So all these parts require a complete refurbishment to get the required profile to keep the crushing efficiency & also at the same time ensuring Life Enhancement of the worn-out components.

The best solution in the industry to give wear protection to all worn-out components is the unique single electrode solution developed by Ador Fontech LH TUFF-TECH 58 for high abrasion & high impact application. LH TUFF-TECH 58 is the ideal alloy for this application since its titanium carbide alloy system in martensitic matrix gives the best wear resistance to abrasion combined with impact outperforming all conventional hardfacing methodologies.

With this single titanium carbide Alloy system LH TUFF-TECH 58, ADFL has replaced the conventional two Electrode combination used as base layer & final layer. The most important aspect is that LH TUFF-TECH 58 outperforms all conventional Alloys with increased life by almost 40% as it gives superior wear resistance to this High Abrasion & Impact application.

The critical advantage with Ador Fontech is that the job can be executed at customer premises while complete refurbishment can be done at our Premises Life Enhancements services facility in Nagpur. Also, for greater customer convenience, this job can be executed through our authorized repair shops at locations close to the plant with trained manpower completely under our supervision.

The complete refurbishment of the horizontal impact crusher is a critical component highlighting the Ador Fontech way of life enhancement of industrial components. Our specially formulated wear solutions ensure Life Enhancement with maximum safety margin at a marginal cost of replacement giving the best value proposition to customers.

Reclaim –Do not replace

Hypertherm: Cutting Made Easy

Four tough jobs made easier with Duramax Hyamp Long torch

We all know that processing metal can be a hard job. It’s hot, dirty, and then there are the physical demands it can put on your body. Metal is heavy, and depending on the size of the plate, difficult to move. It becomes even harder to maneuver when the metal is welded into a sub-assembly or final product. Then to further complicate matters, there are staff shortages, safety concerns, cost constraints, and of course, deadlines to meet.

What if there was a better way to do some jobs? Hypertherm created the Duramax Hyamp Long torch with exactly that aim in mind. Jing Wu, Hypertherm’s lead engineer on this project explains, “We want to help our customers and keep them safe.” Wu and his team based the new handheld torch’s design on what operators told them, and what they themselves observed in shops, yards, and plants. It was clear that “extended reach” is beneficial for several reasons, and by offering longer torch-body lengths, existing Hypertherm -Powermax owners could expand their range of applications.

Hypertherm Cutting Made Easy

 

Here are four jobs that get immediately improved by adding the Duramax Hyamp Long torch to your Hypertherm Cutting System.

1. Skeleton removal

If you’re using oxyacetylene to cut and remove skeletons from your table bed, it’s slowing down your production line. Undoubtedly, Hypertherm Plasma Cutting is faster than oxyfuel but by switching to the Duramax Hyamp Long torch, you can do the same job in a third to a quarter of the time. Existing long torch customers report skeleton removal from heavy industrial CNC beds is so fast, that jobs previously taking an hour, now can be finished in less than 15 to 20 minutes. The savings add up fast.

Hypertherm Cutting Made Easy2. Scrapping

Every scrapper will benefit from having a long torch in their yard. Not only can plasma cut steel, stainless, and aluminum, it cut exotic metals, like copper and brass, and alloys too. The portability of Hypertherm Powermax plasma systems like Powermax 45 & Powermax 65 makes it possible to demolish large-scale depreciated machinery out in the yard, allowing for larger, more lucrative trades with mills. The Duramax Hyamp Long torch is also better than a shear at making long cuts. Plus, it frees up shears to cut the smaller pieces into dimensions required by steel mills, thus making the shear more productive as well.

Hypertherm Cutting Made Easy

3. Structural demolition

Structural steel companies tearing down buildings and other facilities, like decommissioned nuclear plants or sports stadiums, use multiple long torches to speed up the job. Completing the job faster saves on labor costs, but it helps them earn their contractual performance incentives too. Hence this Long torch solution connected with Hypertherm Power systems is most ideal for such jobs.

4. Processing coils, test coupons, and castings

Mills manufacturing steel and other metals are hot places. Furnace’s heat, melt and liquefy raw ore and recycled scrap metal to form new rolled and cast metal products. As noted above, the long torch creates more distance and allows operators to stand further away from the radiant heat, translating to less fatigue and more productivity to customers underlining the benefits of Hypertherm Plasma Systems.

Additional benefits for all four jobs

The Hypertherm Plasma with Duramax Hyamp Long torch is safer to use. It’s ergonomic, allowing operators to work from comfortable positions. The length of the torch body and the angle of the cutting head lets operators stand upright, while still gaining the accessibility they need. Operators avoid back pain that results from having to bend over repeatedly to ignite the flame torch with a striker and operators can stand beside CNC tables, rather than on top of the cutting bed.

This is why Ador Fontech Limited, the name synonymous with total solutions for any Maintenance & Repair solutions offers Hypertherm Duramax Hyamp Long torch as a Robust Cutting solution to our customers.

Reclaim, Do not Replace

Rotary Air Lock – Refurbishment for Life Enhancement

The rotary airlock is an important component for pneumatic conveying, bulk solid handling & batching systems. Rotary airlock or RAL is also known as rotary valve, rotary feeder, or airlock feeder. The main function of RAL is to control the flow of bulk solids from the silo, mixer, cyclone, or hopper even in mills so the material is transported under gravity, pressure, and vacuum conditions.

In a cement plant, it is primarily used as a mechanism for feeding limestone, clinker, and cement to the mills. The main function of this valve mechanism is delivering the various ores (limestone, clinker, or cement) into the mill without the mixing of false/ambient air. The unintended mixing of ambient air has an adverse impact on cement machinery by reducing the performance & life, hence it’s widely used in all areas where control of feeding is required.

RAL consists of a rotor bucket mounted on a casing. This rotary system gets worn out due to high grinding abrasion, moderate impact & erosion caused by the continuous flow of abrasive material like limestone (Clinker or cement) through the valve.

Rotary Air Lock Refurbishment for Life Enhancement

RAL is a key component in the cement industry that requires complete refurbishment of all components. The main parts damaged are the RAL casing including side covers, liners, rotor & rotor blades. So all the parts are completely replaced with our Life Enhancement solution including the shaft which gives the rotary action to the equipment.

Ador Fontech’s solution to this problem is a complete dismantling of RAL components and repair & fabrication of all parts. The complete welding is done with our special Alloy LH-1105 having the best hydroscopic property and very high tensile strength ideal for joining applications. All the buckets are given wear protection with Hardox wear plates. Complete Machining & alignment is done in a VTL ensuring all vital parameters are maintained for enhanced performance & Life Enhancement of refurbished RAL.

Rotary Air Lock Refurbishment for Life Enhancement

Ador Fontech brings you a state-of-the-art LE services facility in Nagpur, which specializes in this kind of precision job having executed more than 100+ RAL refurbishments for the Cement Industry in India. The unique capability of Ador Fontech is the experience in manufacturing and refurbishment of RALs from 650 Diameter to 2200 diameter.

Rotary Air Lock Refurbishment for Life Enhancement

The complete refurbishment of rotary airlock signifies our policy of Life Enhancement of industrial components in the Ador Fontech way using specially formulated wear solutions to ensure Life Enhancement with maximum safety margin at a marginal cost of replacement with new RAL ensuring the best value proposition to the customer while re-enforcing our ideals of Reclaim –Do not Replace…

Resolve Wear Factors using Effective Hardfacing Electrodes

In any discussion of welding on wear-prone applications, reference is made to the hardness of weld deposits & what hardfacing electrode can be used for different applications. But the word “hard facing” is actually a misnomer. In reality, what any maintenance engineer in any plant is looking for is an ideal solution to tackle the wear in the particular application. So, in essence, the engineer is looking for a wear-facing product with the necessary properties to tackle the wear. not just hardness.

So, to understand the effective use of hard-facing welding electrodes, we need to understand what is wear & and learn more about the wear factors. Wear can be described as the process of constant loss of material or material integrity from a solid surface. Wear is a surface phenomenon and generally, causes of wear can be mechanical or chemical. The study of wear and related processes is also known as Tribology.

The factors of wear can be classified into two types –Primary wear factors & Secondary wear factors.

Primary Wear Factors-Abrasion, Friction & Impact

Secondary Wear Factors-Erosion, Corrosion, Heat, Cavitation

The seven factors listed above can all act on any component, causing the wearing out. There are various methods and solutions available to help combat these wear factors. However, let us first look at why we have classified them separately as primary and secondary wear factors.

The reason is really simple. The primary wear factors of Abrasion, Friction & Impact in general in all industry applications cause more loss of material or wear when compared to the secondary factors. Hence it is critically important to suggest solutions to combat the primary wear. Invariably, we find that some secondary wear factors also accelerate the wear. So, when we suggest solutions for any application, we need to study all the wear factors acting on the application and provide a comprehensive solution.

Typical Example: Let’s take the application of boiler nozzle tip in a power plant. Pulverized coal passes through the boiler tips in a power plant wearing down the component with high impact and abrasion. But, the wear is actually accelerated by the secondary wear factors of Heat, corrosion & Erosion as materials are carried by forced air when it is moving inside the boiler. So we need to select an LH Alloycapable of withstanding all these wear factors. Ador Fontech’sLH 743Nis a special constituent alloy that retains its hardness even at 650 degrees Celsius, making it the most suitable solution for this application, capable of dealing with the multiple wear factors.

One of the unique insights gained from studying the tribology of wear is that all applications in the industry will have a combination of wear factors. There is almost no application across the industry where we have only one wear factor. So when we offer a solution we need to understand the combination of wear factors acting on the component to provide a solution that ensures Life Enhancement.

This is the reason why we must understand the term hard facing. We must know that simple hardness in the application does not assure us of a component’s longer life. We get longer life with a correct LH Alloy which can tackle all the critical wear areas in the industry and offers the correct alloy combination & hardness. Let us see some industry examples to understand the concept of Wear facing using different Hardfacing alloys.

Typical applications you see in cement plant mines, steel plant mines, and in all mining area applications are repairing the hardfacing material of handling buckets in wheel loaders and porcelain machines. Typically, with the type of ore or material handled – limestone, iron ore, or coal, the normal wear factors in the application would be high abrasion caused by non-metallic particles on metal combined with impact. So it may be assumed that simple high Iron carbide deposits with 60 HRChardness should ensure a good life.

Resolve Wear Factors using Effective Hardfacing Electrodes

But in reality, we need to look at the application on-site and observe the terrain or conditions under which it is working. It may be working in the slushy and muddy conditions in high monsoon areas. It’s the type of customer who uses a lot of water to keep the environment friendly. Actually, we need a product with erosion and corrosion resistance. This means we need an Alloy that contains Chromium. Such subtle addition of alloying elements gives longer life. Even for this kind of application, Ador Fontech offers a solution with additional Chromium. For e.g., a product like LH 720 gives excellent Life Enhancement in comparison to conventional hardfacing electrodes with wear protection on secondary wear factors of corrosion and erosion Let us look at a second scenario.

Crushers are used in mining to crush raw material. Depending on the type of industry, we have horizontal impact crusher equipment or hammer crushers with discs. These are widely used in this kind of application because the size of the particles and speed of crushing subject these components to very high impact combined with abrasion. To get the best results, it’s important to use a material with the correct microstructure to withstand the wear factors in such an application.

Normal Fe-Cr-C alloy system Special ADFL alloy system for impact application-

Resolve Wear Factors using Effective Hardfacing ElectrodesResolve Wear Factors using Effective Hardfacing Electrodes

The above illustration shows two different carbide microstructures. The bigger carbide microstructure on the left fails as carbides are chipped off with high impact loading. The minutely, or evenly, distributed carbide on the right is best suited for a high impact & abrasion application and gives better life than the normal coarse carbide microstructure. The carbides are very difficult to dislodge because of the close fine carbide structure. At Ador Fontech, we have developed this special Alloy hardfacing electrode for high impact & abrasion application giving it the highest life enhancement with maximum productivity.

We hope the above salient points on tribology of wear and the three examples explain the problems with wear facing welding electrodes. Ador Fontech brings you a complete range of welding electrodes & Alloys to combat all wear factors. The most critical aspect of this range is that the solution comes in either welding electrode form or as open arc wires, to meet your application’s requirements.

Life enhancement of industrial components has formed the cornerstone of the services offered by Ador Fontech Limited, over the last 40 years and more. Partner with us to maintain and repair your equipment for tangible savings with minimum downtime and the highest productivity. Benefit the environment by conserving the non-renewable metal resources of the world.

Reclaim, Do Not Replace

Nickel- Of Vital Importance in Cast Iron Welding

The main problem with welding cast iron comes from its high carbon content. During the welding process, this carbon migrates into the weld metal and/or the heat-affected zone adjacent to the weld metal, making it hard & brittle. This is how Cast Iron gets its reputation for post-weld cracking.

Hence the key to welding cast iron lies in eliminating the risks posed by this higher carbon content which reduces its elongation to about 1%.

Cast Iron in Industry:

Cast iron is a ferrous alloy that has more than 2% carbon in it. Though it can contain anywhere from 2% to 6.67%of carbon, practically it is found to be between 2% to 4%. Other alloying elements & types of Cast Iron used generally are listed in the table below:

Nickel- Of Vital Importance in Cast Iron Welding

Advantages of Cast Iron

•It has good casting properties.
•It is available in large quantities, hence produced on a mass scale. Tools required for the casting process are relatively cheap and inexpensive, resulting in low cost of products.
•It can be given any complex shape and size without using costly machining operations.
•It has three to five times more compression strength compared to steel.
•It has good machinability (gray cast iron)
•It has excellent anti-vibration (or damping) properties, hence it is used to make machine frames.
•It has resistance to deformation.

Disadvantages of Cast Iron

•It is prone to rust & loss of Strength.
•Its parts are section-sensitive; due to the slow cooling of thick sections.
•Failure of its parts can be sudden and total parts are crack sensitive
•It has high brittleness.

Applications of Cast Iron

Cast iron is used in making the following products
•Pipes, to carry suitable fluids.
•Different machines
•Automotive parts
•Pots, pans and utensils
•Anchors for ships
•Machine bases

Nickel- Of Vital Importance in Cast Iron Welding

Importance of Repairing Cast Iron Components:

Cast iron is widely used in diverse industries with its inherent advantages. It is crack sensitive and also has a reputation of being difficult to weld because of its high percentage of carbon and less conductivity. It is also one of the prime examples for Ador Fontech to showcase our product & process expertise. We not only overcome this problem to successfully repair cast iron components but also give them an even better life than the original components.

Why is Nickel Vital to the Repair?

Nickel-based alloys & high Nickel electrodes are basically used in the welding of all weldable cast Iron as its offers excellent solubility of its carbon component and it’s also a more ductile weld metal. Nickel electrodes also help to reduce the pre-heating and HAZ cracking by providing less carbon pick up in the weld area & the heat-affected zones around weld joints. In all cases, care should be taken to minimize heat input to the base metal. Hence Low Heat Input Welding Alloys like LH 119 & LH CastHeal 113F offer the best solution totally eliminating post-weld cracks. They give a safe and sound joint with considerable Life Enhancement to any broken component.

Ador Fontech expertise in Cast Iron Welding:

From the moment we started our operations in the maintenance & repair welding business 4 decades ago, we had introduced novel products for welding cast iron with products like LH 115 & LH 119. These alloys offer special low heat input properties and unparalleled performance in the last 40 years with our unique methodology of cold welding in Cast Iron components with proprietary expertise in hand heat method.

Today, we offer a complete range of Nickel Alloys in welding Electrodes and in wire form, both TIG and MIG, to take care of all the welding needs of our valued customers. We, at Ador Fontech, take pride in saving thousands of components with our Low Heat input-LH Philosophy to ensure savings in inventory and higher productivity through the Life Enhancement of repaired components.

Reclaim, Do Not Replace

Application of LH Welding Alloys in the Cement Industry

Welding is an important component in the core sector industry driving the infrastructure world – Cement. One of the basic fulcrums which drives this process industry is the maintenance and repair of cement Industry components. Cement is basically manufactured from the raw material ore of Limestone hence the process starts at the mines and ends up as a final product in the Cement Plant. So underlying theme in the manufacturing of cement is Wear –primarily abrasive wear caused by hard limestone combined with impact, heat & erosion in the process.

Application of LH Welding Alloys in the Cement Industry

Why do we use LH welding Alloys in cement plants? This is an important question to answer as most of the material we are going to weld or repair undergo thermal fatigue and continuous wear & tear. Hence welding with the lowest possible amperage with minimal effect on the stressed and overworked component is very important also electrodes to suit welding of dissimilar metals. hence this forms the basis for the repair of all cement Industry components.

The modes of repair by welding can be divided into three types.
1. Protective Maintenance of Wearing Components
2. Maintenance & Repair of worn-out components
3. Breakdown Repairs with highly reliable Components

Now let’s see the three types of repair in detail to understand more about welding cement industry components-

• Protective maintenance:

We understood that the manufacturing of cement involves handling hard limestone meaning very high abrasive condition with impact, heat, and erosion. Hence in many cases, the base material of the component needs protection. This can be as simple as wear protective welding in new components like earth moving buckets or rotary airlock valves designed to give long life before they get worn out with tailor-made solutions like Endurafon & Hardox ready-to-use wear plates.

Application of LH Welding Alloys in the Cement Industry

• Maintenance & repair of worn-out components:

True to its name, this process involves the repair of worn-out components with low heat input LH welding alloys to ensure prolonged life or improved life of the worn-out components prone to abrasion and moderate impact. Some of the typical applications can be impactor arm in mines, Sinter cast roll buttoning in VRM roller and RPR pattern welding build-up with a product designed to perfection like LH Tuff-Tech 58 & LH Weartherm 65.

• Breakdown Repair or Maintenance:

The cement industry is a process industry, hence certain components fail due to heavy loads, heat, material fatigue. It’s very difficult to have inventory for these components. Hence these components need in –situ repairs of parts with maximum reliability and performance. Some critical examples are kiln tyre or kiln girth gear. We carry out these repairs with our Star products LH Gold 555 & LH 521 ideal for welding dissimilar metals or known and unknown combination of steels.

Application of LH Welding Alloys in the Cement Industry

It is a matter of pride for Ador Fontech, that our name remains the first one recalled by all our Cement Industry customers when they’re faced with maintenance & repair welding requirements. We offer tailor-made solutions using specially manufactured Low Heat Input (LH) welding Alloys, Wires, and ready-to-use wear plates for all the above welding solutions.

Ador Fontech brings 4 decades of experience in managing all types of applications e.g. joining wear-prone areas & cutting solutions required by valued customers from the cement manufacturing industry. One of the key advantages with ADFL is that apart from supplying the product, we can also carry out repairs at our centralized workshop at Life Enhancement Services, Nagpur. This dedicated site takes up the repair of all cement industry components. We also have a dedicated supply and repair team which offers all maintenance and welding repair solutions at the customer’s site.

This is what makes Ador Fontech’sname synonymous with total solutions for any maintenance & repair problem to the complete satisfaction of customers.

Reclaim, Do Not Replace.