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WELCOMES Protecting the world from wear European Centre Patented Bulk-welding Process • • Developed and patented by company founder Roman F. Arnoldy in 1961. Continuously developed and improved over the years. Bulk-welding Process Open arc Continuous Wire Electrode Direction of Travel Metal Powder Submerged arc Continuous Wire Electrode Weld Overlay Direction of Travel Substrate Flux Metal Powder Unfused Flux Fused Flux Weld Overlay Substrate Bulk-welding Process Open arc Continuous Wire Electrode Direction of Travel Tailor-made alloys achieved by varying power mix Metal Powder Submerged arc Continuous Wire Electrode Weld Overlay Direction of Travel Substrate Flux Metal Powder Unfused Flux Fused Flux Weld Overlay Substrate Overlay Plate Triten Range – Open Arc • • • • • Produced on continuously turning drum. Plate rolled to correct diameter to produce 2 plates 1500 X 3000. 4 oscillating welding heads. Cut in half then passed through flattening rolls. Full traceability. Triten Range Summary T153X Impact Resistance T137X T200X T214X T211X T237X T223X Abrasion Resistance Trimay Range – Submerged Arc • • • • • Plate products either on drum or flat. Technique used for welding hardfaced rolls. Flux powder buries the arc thus slower weld pool cooling. Flatter product. Ideal for dynamic applications. Trimay Range Summary Impact Resistance T156 T157 T45 T165 T164 Abrasion Resistance Overlay Plate General Characteristics • Triten APG produces plate products using both the open-arc and the submerged arc process • Generally similar products • With a few important differences Overlay Plate General Characteristics • • Stress Cracking is a Desirable Feature Substrate A Critical Factor • • • Tough yet ductile High strength Corrosion & temperature resistant Overlay Plate High yield strength substrates reduce the overall thickness of the protection Overlay Standard base material S 275 Overlay High yield base material S 690 Overlay Plate In a corrosive environment although the overlay has good corrosion resistant properties, the S275 base material may be unsuitable Overlay Standard base material S 275 Overlay Plate A stainless steel base plate provides good support for the overlay and protects the overall product from corrosion. Overlay Stainless steel base AISI A304 / 316 / 310 Most Common Overlay Typical Composition • 4-5 % Carbon • 25-35% Chromium T200X Manufactured Using Carbon Ferro- Chrome-Powders T200X Austenitic Eutectic Matrix Primary Chromium Carbides Complex Overlay Alloys T223X High Chromium Iron, with Niobium, Molybdenum, Tungsten and Vanadium T223X HIGH TEMPERATURE PERFORMANCE UP TO 650Oc T223X Austenitic Eutectic Matrix Primary Chromium Carbides Complex Mo, V, W Carbides. Added Nb carbides A Wide Choice of Thicknesses & Alloys 35 Thicker overlays EXCEPTIONAL WEAR RESISTANCE 30 25 FORMING THICK & THIN PLATES 20 15 10 5 0 Thinner overlays IDEAL FOR DYNAMIC APPLICATIONS Questions + Answers • The client wants to make a coal handling chute from T200X, he is worried about the sticky nature of the wet coal : – With the overlay positioned in the same direction as the material flow, the sliding coefficient is very good. The material polishes in service almost to a mirror finish (30% Cr) • The client is uncertain as to the correct overlay direction on cut to size pieces : – For most applications, this will not affect the lifetime of the component. In an abrasive environment with a high level of errosion (small granular size), the overlay should be placed at 45° to avoid errosion between the weld beads. • Can the overlay come away from the base material? : – This will not happen with a quality product, there is a perfect bond between the two materials (weld). The product conforms to the international standard for clad plates. Questions + Answers • Do overlay plates resist to impact? : – It is true that as a general rule, overlay materials are better adapted to the problems linked to tangential abrasion. A quality product can absorb « moderate to high » impact, each application must be studied. • Overlay plate with 30% Cr has good corrosion resistant properties, doesn’t it? : – The alloy does indeed have excellent corrosion resistant properties, the mild steel base plate however certainly does not. We can consider other products with a stainless steel base in 304 or 316 for example (even 310). • He client insists on having countersunk holes in the liners, but finds the cost of inserts to be too high : – The best solution is an inclined plasma torch, this gives a perfectly acceptable hole quality and costs significantly less than welded inserts. Roll Manufacture & Repair Hardfacing Directly Onto Cylindrical Rolls • Steel Mills • Cement Works • Food Processing Typical Rolls In Steel Manufacture Up to300 Run-Out rolls in this area Various table rolls. Scale breaker pinch roll Downcoiler wrapper rolls, deflector rolls, top & bottom pinch rolls HARDFACED ROLL MANUFACTURE & REFURBISHMENT Concast Operation 1. Foot mould rolls 2. Strand guide rolls 4. Cut-off table rolls 3. Straightening rolls 5. Table rolls HARDFACED ROLL MANUFACTURE & REFURBISHMENT Roll Manufacture & Repair Wide Range of Alloys Deposited • Cement Industry Slag Crusher Rolls • • • H11 Tool Steel Overlay Crack-free Surface Prevents Cement Entrapment Allowing On-Site Repair On-site Hardfacing Armalloy Tubular Hardfacing Electrodes • • Available in standard and nonstandard alloy products Localised Protection for Bucket Teeth, Auger Flights, etc. OVERLAY PLATE MANUFACTURE & FABRICATION ROLL MANUFACTURE & REFURBISHMENT HARDFACING ELECTRODES Delivering practical benefits for end-users... • • • • • • • • • • Steel Cement Power Generation Sugar Mills Mining Earth Moving Pulp & Paper Refining & Petrochemical Dredging Glass Manufacturing PROTECTING THE WORLD FROM WEAR ALL-STAL www.all-stal.pl