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CUTTING
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Both Tritens chromium and tungsten carbide alloy hardfacing overlay act like stainless steel
during cutting. This precludes the use of conventional shearing or oxy-fuel flame cutting
processes.
There cutting methods can be used:
Plasma Arc
Carbon arc
Abrasive saw
Diameter
Up to
6.3mm
1/4
Amperage
Minimum
Recommended
(DC
Air Flow
250-400A
Reverse
3cfm @
100
Air Flow
Polarity)
40psi
l/min
l/min
@3
@6
9 cfm @ 80psi
300
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Bar
9.5mm &
3/8
350-600A
above
Bar
6cfm @
200
15 cfm @ 80psi
500
90psi
l/min
l/min
@6
6 Bar
Bar
Cutting should be carried out from the carbon steel side of the plate by first marking out the cutting lines and then
dot punching to ensure continued visibility during the process. After cutting plates from the substrate side, all
slag should be removed with an abrasive grinding disc.
Abrasive Saw
Limited straight line cutting can also be achieved using an abrasive saw (as used to cut concrete) fitting with
silicon carbide wheel.
COLD FORMING
Most standard grade of Triten overlay plate can be
cold formed into curved and conical sections using
either rolls or press brakes. Triten T214X has only
limited form-ability and a number of special
chromium/tungsten and tungsten carbide grades can
only be used as flat profiles and fabrications.
Convex forming has the effect of increasing and/or widening the stress relief cracks
within the alloy facing. Experience shows that this should not present problems if the
minimum recommended radius is not exceeded. Above this figure there is an
increasing chance of spalling and crack propagation into the carbide steel/substrate.
Concave forming puts the alloy facing into compression and the substrate into
tension and has the effect on closing the stress relief cracks within the the alloy
facing. The high compressive strength of the overlay combined with the ductility of
the substrate allows far small diameters to be formed.
Direction of Rolling
Wherever possible, plates should be formed with the weld beads aligned in the direction of rolling. (See figure 1).
Minimum Diameters
The minimum recommended diameter to which Triten overlay plate can be formed will depend on the thickness
of the plate, the type of substrate and whether the bend is concave (alloy facing on the inside) or convex (alloy
facing on the outside). See figure 2.
The table below shows typical minimum diameters for cold forming* T200X plate.
Triten
Nominal
Minimum
Minimum
Grades
substrate
Diameter
Diameter
T200X
thicknesses
Concave
Convex
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Single layer
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9.5mm (3/8)
400mm (10)
250mm (16)
12.5mm (1/2)
450mm (16)
400mm (18)
overlays
from
3.2-6.3mm
)1/8
2/4)
Double
layer
overlays
from
8.0-12.5mm
(5/16
3/8)
When using pyramid or pinch rolls, it is recommended that the top roll is protected with a sleeve to prevent
damage to the hardfacing. This should be fabricated from 12 mm (1/2) thick carbon steel and sized
approximately 50 mm (2) larger than the roll diameter to facilitate installation and removal and to prevent
binding.
When using a brake press from small diameter pipe, cones and square to round transitions, it is recommended
that a hydraulic press is employed for the best results. Forming can be carried out with a male and female die,
using a radiused top tool (min. 38cm/ 11/2) over a V block.
HOT FORMING
For thicknesses above 20mm (3/4) forming can be assisted by the application of heat either locally, using a broad
flame oxy-gas torch, or generally for larger sections, in a furnace.
To ensure that there are no significant changes in the properties of the plate, hot forming
temperatures should not normally exceed 650C (1,200F), with furnace soaking times of no more
than 1 hour. Higher temperatures may be used in special circumstances.
Further information on forming individual plate grades and thicknesses and specific forming techniques can be
obtained from Kubes Alloys directly.
Hot forming is recommended where 90 degree corners are needed when fabricating square to round transitions.
Special Substrates: Where high strength alloy steel substrates are used, whether in cold or hot forming, more
power will be required to form the plate to the same diameters as conventional carbon steel substrates.
FABRICATION
Flat profiles and formed sections can be fabricated into larger items or finished structures using conventional
welding procedures. Liners may be fixed to existing structures by bolting or by various welding techniques.
All structural welds must be applied to to the substrate.
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weld. This is best achieved by stopping the fillet approximately 3mm (1/8) below the alloy/base plate interface
which should be clearly visible on a ground edge.
Any common welding process may be used including:
Shielded metal arc welding (US SMAW) / Manual metal arc welding (UK MMA)
Gas metal arc welding (GMAW) using solid wire.
Flux cored arc welding (FCAW) using gas shielded or open arc wires.
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carbon steel. When gouging plates thicker than 9.5mm (3/8) it is recommended that a hole is first drilled into
the substrate to stop just short of the alloy interface before gouging is started.
All slag should be removed from the fixing holes by grinding or chipping/hammering.
The plate is then attached to the structure by welding the outside diameter of the hole through 360 degrees and
then filing the remaining space using the pattern shown in figure 4.
The thickness of the weld should be determined using the same criteria as for fillet welding and should stop 3mm
(1/8) short of the overlay alloy layer. When the weld has been filled to the desired level, it can be protected from
abrasion by capping with a suitable wear resistant alloy using Triten Armolloy tubular hardfacing rods
(electrodes).
Suitable holes for countersunk bolts may be produced by direct plasma arc cutting using an orbital tool post, by
piercing or gouging a straight hole and welding a pre-machined insert in place, or by a combination of direct
drilling or gouging.
The minimum recommended bolt size is 9.5mm (3/8) diameter and the number and spacing required will
depend upon the size and shape of the plate.
The finished counter sunk hole should allow the flat headed bolt to sit approximately 4mm below the surface of
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the plate. It can be protected from abrasion by capping with a suitable Triten Armalloy tubular hardfacing
electrode.
Pre-machined inserts
Accurate pre-machined inserts may be used to fix overlay plates by cutting a straight hole in the plate and welding
the insert in place from the carbon steel side.
Plasma arc cutting from the hardfaced side of the plate is recommended because is creates a naturally tapered
hole which provides additional support for the insert.
The insert should be machined with a taper of around 3 degrees to
match the hole and a chamfered weld preparation cut into the base. It
is then welded into place from the carbon steel side using a low
hydrogen electrode (AWS 5.1 E7018 or 7016 type).
Gouging
This process is generally used on-site when plasma-arc cutting is not available. If a large number of holes is
required, welded inserts are recommended and gouging should be used purely to cut the clearance hole.
An alternative method for one or two holes involves gouging a straight hole from the carbon steel side (see also
cutting). The countersunk section is then created be gouging a taper from the hardfaced side. The holes may be
cleaned with abrasive cone/plug shaped grinding stones.
STRUCTURAL WELDING
Triten overlay plate can be fabricated by welding the mild steel substrate using standard mild steel or low
hydrogen electrodes. The following details are a general guide to welding Triten overlay plate.
Care must be taken to ensure that all structural welds stop short of the hardfacing alloy layer. The
only welding carried out on the hardfaced side of the plate will involve the capping of joints, for
wear protection, with a compatible Triten Armalloy tubular hardfacing electrode.
Fillet welds
Grind the edge of the plate to remove any slag and scale left from cutting. Care should be taken to ensure that the
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weld is applied to the substrate only and does not overlap the hardfacing or its penetration zone, as this can lead
to carbon contamination and embrittlement of the weld and the adjacent area. This is best achieved by stopping
the fillet approximately 3mm (1/8) below the overlay/base plate interface which should be clearly visible on a
ground edge. (See figure 3).
Butt Welds
Partial penetration butt welds involve cutting a bevel into the carbon steel base by gouging or flame cutting (see
figure 6). A 2 mm to 3mm (1/16-1/8) land should be left to prevent
burn-through to the hardfaced layer when welding (see figure 7). Fit
and tack sections, then weld using the same technique as conventional
joining.
AWS
E7018
5.1
(SMAW)
AWS
E703-6
A5.18
(GMAW)
with75%
AWS
E70T-1
Argon
Note:
Where
the
fabrication
proves difficult to align with sufficient accuracy to ensure that no
A5.20
(FCAW)
25% CO
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contamination by the hardfacing is likely during welding, it is recommended that a 309 type
stainless steel welding rod (electrode) be used.
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