Welding Repair On Steel and Cast Iron PDF

Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services By Sabandi
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org
Abstract
Some electrode special designed for welding repair and maintenance
On heavy equipment part , industrial equipment and drilling equipment for
oil and gas industries.
Problem on repair welding on heavy equipment part , industrial

equipment and drilling equipment for oil and gas.
Cracking when welding or delay cracking.

Shrinkage Stress
Hardness in (HAZ) Heat Affected Zone.
Need PREHEATING before welding.

The needed for pre-heating increases with following factor bellow :
Carbon content on Base Material

Metal Alloy on Base material
Dimension of Base Material (thickness etc)
Initial temperature
Welding speed
Diameter of consumable
Determine the pre-heating temperature based on carbon equivalent
of chemical composition on Base Material.
Ceq = %C + %Mn /6 + (%Cr + % Mo + %V) / 5 + (%Ni + %Cu)/15
If Ceq increase , Pre-Heating needed increase

CONTROLLING WELD METAL DILUTION
Dilution is the inevitable mixture of the base material and weld metal
deposit when welding
The objective is to keep the dilution as low as possible to obtain the

optimum properties in the hardfacing deposit
Dilution
Area

Factors influencing dilution
1. Welding Seed (Slow speed Dilution , High speed Dilution )
2. Welding Polarity
DCEN Low Dilution
AC Intermediate Dilution
DCEP High Dilution
3. Heat Input
Low HI Low Dilution
High HI High Dilution
4. Welding Technique
Stringer beads Low Dilution
Weave beads High Dilution
Buffer Layer / Buttering
Buffer Layer are used as

intermediate deposit between the
base material and the actual
Hard facing weld metal to :
Ensure good bonding with the
base metal
Avoid hydrogen-induce under
bead cracking even on
preheated work pieces.
Minimize consequences of
Stress
Limit the effect of dilution.
Prevent possible crack in the
hard-facing layer running into USE AUSTENITE CONSUMABLE FOR
the base material. BUFFER LAYER

WELDING CAST IRON
Cast iron is alloy iron with carbon with

content %C 2-5 % , Silicon 1-3 % and
manganese 1%.
Characteristic cast iron low ductility, low
hardness, low strength and generally a
very brittle material. To improve these
properties, cast iron is very often
alloyed or heat-treated.
The type cast iron mainly used to day :

Grey Iron
Nodular Iron
Malleable Iron
Compact Graphite
White Iron

Electrode for repair Cast Iron
1. Pure Nickel Type electrode

2. Nickel-iron type electrode
3. Nickel-cupper type electrode

WELDING MANGANESE STEEL
Manganese steel some time called

austenitic manganese steel with
contain %C 1- 1.4 % and 11-14 %
manganese.
Characteristic Manganese Steel.

Ability to Work harden during cold
working
High Impact
High surface pressure
Usually manganese steel used for

Crushing and mining industry for
example crusher hammer, tumbler,
bucket, digger teeth and rail point. Repairing chrusher 14% Mn
steel
The weld ability of manganese steel is restricted by its tendency
to become brittle upon re-heating and slow cooling.
One rule of tumb is that the interpass temperature must not
exceed 200 oC
CONTROL HEAT INPUT During welding essential.
Technique welding for Manganese Steel

Low Heat input welding ( Low Current)
Stringer bead welding
Speed cooling
Electrode for Joining AWS 5.4 E 307-16 (C=0.1 , Cr=18%, Ni=9%)
Electrode for Hardfacing / Surfacing , Buffer layer with AWS E

307-16 and hardfacing with E 7-200-K (%C= 1.1 and Mn = 13% )

Sample of repair work
Crusher teeth Buffer layer E 307-16 , hardfacing E10-60 (OK

84.78) %C 4.5 & Cr 33%, welding process SMAW
Re-Build Crusher Hummer (OK 15.65) DIN 8555 composition
C 0.9%, Si 0.4%, Mn13%, Ni 3% Welding Process FCAW
Hardfacing Support Roll
Buffer layer (OK 84.52)
DIN 8555 composition C
0.25%, Cr 13%,
Hardfacing AWS 5.13
ECoCr-A (OK 93.06)
Welding Process SMAW

Hardfacing Teeth Exapator (OK 84.58) %C 0.7, Si 0.6%, Mn
0.7% & Cr 10%, welding process SMAW
Hardfacing Tumbler (OK 84.84) %C 3.0, Si 2.0%, Cr 8.0%, V
6.0% & Ti 6.0%, welding process SMAW
Repair Oil & Gas Drill Tools
Stabillizer drill tool, build up 304L powder and

Hardfacing Tungstent Carbide welding Process
PTAW
Repairing Drill Bit
Built up OK 83.28
(C 0.1% & Cr 3.2%)
Before Repair Hardfacing
OK 84.84 (E 10-60-
GP)
Welding Process
SMAW
After Repair
Rail Repair
Mould Welding OK 74.74

Tram Line Repair
Electrode AWS 5.4
307-15 (OK 67.52)
Composition :
C 0.1%, Mn 6%, Cr
18%, Ni 9%
Welding Process
SMAW

Wheel Burn Repair
Filler OK Tubrodur 15.43
composition : C 0.15%, Cr
1.0%, Ni 2.3% and Mo 0.5%
Welding Process FCAW
THANK YOU


Welding Repair On Steel and Cast Iron PDF

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Indonesian Welding Society (IWS)

Problem on repair welding on heavy equipment part , industrial

Cracking when welding or delay cracking.

Need PREHEATING before welding.

Indonesian Welding Society (IWS)

Carbon content on Base Material

Ceq = %C + %Mn /6 + (%Cr + % Mo + %V) / 5 + (%Ni + %Cu)/15

If Ceq increase , Pre-Heating needed increase

Indonesian Welding Society (IWS)

The objective is to keep the dilution as low as possible to obtain the

Indonesian Welding Society (IWS)

Buffer Layer are used as

Indonesian Welding Society (IWS)

Cast iron is alloy iron with carbon with

The type cast iron mainly used to day :

Indonesian Welding Society (IWS)

1. Pure Nickel Type electrode

Indonesian Welding Society (IWS)

Manganese steel some time called

Characteristic Manganese Steel.

Usually manganese steel used for

Technique welding for Manganese Steel

Electrode for Joining AWS 5.4 E 307-16 (C=0.1 , Cr=18%, Ni=9%)

Electrode for Hardfacing / Surfacing , Buffer layer with AWS E

Indonesian Welding Society (IWS)

Crusher teeth Buffer layer E 307-16 , hardfacing E10-60 (OK

Indonesian Welding Society (IWS)

Stabillizer drill tool, build up 304L powder and

Mould Welding OK 74.74

Indonesian Welding Society (IWS)

Indonesian Welding Society (IWS)

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