Presentation on Stellite hardfacing repair
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Following presentation shows how to overcome the hardfacing problems by introducing a new welding procedure known as Buffering process.
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The flash-butt welding process involves pressing two rail ends together under high pressure after heating them to melting temperature with a high-current electric arc. This causes the ends to coalesce into an accurate weld without filler metal and with a minimal heat-affected zone. To prevent issues with track geometry after cooling, the rail ends are given a slight upward inclination matched to the rail profile. Flash-butt welding produces welds with strength nearly equal to the parent rail and a very low failure rate compared to other welding methods like aluminum thermic welding. Mobile flash-butt welding machines can perform this process automatically on site along rail lines.
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The flash-butt welding process involves pressing two rail ends together under high pressure after heating them to melting temperature with a high-current electric arc. This causes the ends to coalesce into an accurate weld without filler metal and with a minimal heat-affected zone. To prevent issues with track geometry after cooling, the rail ends are given a slight upward inclination matched to the rail profile. Flash-butt welding produces welds with strength nearly equal to the parent rail and a very low failure rate compared to other welding methods like aluminum thermic welding. Mobile flash-butt welding machines can perform this process automatically on site along rail lines.
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Welding is a process that joins materials by causing fusion and filling the joint with a filler material. There are several advantages to welding including lighter structures, maximum strength in joints, easy alterations, pleasing appearance, and strength equal to the parent material. Spot welding uses two electrodes to locally fuse materials and is commonly used in automotive and aircraft industries to join sheet metal. MIG welding uses an inert gas shield to prevent contamination and is often used for carbon/alloy steels, stainless steel, aluminum and other metals due to its high welding speed and economy. Common welding defects include lack of penetration, undercut, slag inclusion, porosity, cracks, spatter, and distortion.
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The document outlines the requirements for nine grades of hot rolled low, medium, and high tensile structural steel according to the Indian Standard 2062:2006. It specifies chemical composition limits and mechanical properties for each grade. It also describes testing requirements, including tensile testing, bend testing, and impact testing to ensure the steel meets specifications. Defect and freedom from defect standards are provided as well as permissible variations in chemical analysis and testing positions.
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The document outlines Indian Standard 2062:2006 which specifies requirements for nine grades of hot rolled low, medium, and high tensile structural steel. It describes the chemical composition, mechanical properties, permissible variations, testing procedures, and other quality requirements for the steel grades. Destructive and non-destructive tests are specified to ensure freedom from defects and compliance with mechanical properties.
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Presentation on Stellite hardfacing repair
- 1. By Gaurav Kale. Sponsored Industry: KOSO INDIA, Pvt. Ltd, Nashik. K.K. Wagh Institute of Engg. Education & Research, Nashik
- 2. Hardfacing is a metalworking process where harder or tougher material is applied to a base metal. WHAT IS HARDFACING? Before Hardfacing: After Hardfacing:
- 3. Hardfacing Materials: 1. Stellite: • Grade 6 • Grade 12 Sr.No. Elements (%) Grade 6 Grade 12 1 Carbon 0.9-1.4 1.2-1.7 2 Silicon 2 1 3 Manganese 1 2 4 Phosphorous 0.016 0.016 5 Sulphur 0.015 0.015 6 Chromium 26-32 26-32 7 Nickel 3 3 8 Molybdenum 1 1 9 Iron 3 3 10 Tungsten 3-6 7-9.5 11 Cobalt Remaining (min 60%) Remaining (min 60%)
- 4. FLAWS DURING HARDFACING: Currently the industry is facing some problems in this (Hardfacing) processes such as, 1. Cracks. 2. Porosity 3. Blowholes.. Cracks in the specimen:
- 5. Flaws overcome strategies: Modify the present Welding Process Specification(WPS). Suggest the new procedure according to the metallurgical properties of work piece if any.
- 6. Our Research and study: Removing flaws not possible just by modifying the present WPS. We found a process in which the base metal is welded first with intermediate hardness material. • The process is known as Buffering Process.
- 7. In buffering process, the material of intermediate hardness between alloy steel and stellite is hardfaced first on valve part and then hardfacing of stellite is done. Here, we are using stainless steel for buffering. Buffering Process:
- 8. Specimen creation: Diameter : 100mm Thickness:40mm
- 9. OUR OBSERVATIONS: Stellite reacts differently with alloy steels. Alloy steel is softer compared to cast steel
- 10. Hardfacing on alloy steel job with conventional method:
- 11. Observations for hardfacing (With convensional method): Parameter Observations Rotation speed meter 0.42 RPM Powder speed 11.6 gm/min Voltmeter 19.6 V Ammeter 120 A Powder gas 3.7 LPM Center gas 2.6 LPM Shield gas 6 LPM
- 13. Buffering process observations: Welding process GMAW welding Buffer Material SS 316L. Preheat temperature 100-150℃ Interpass temperature 150℃ Current 182 A
- 14. •Stainless Steel. •Manganese Steel. •Nickel based steel. •Copper based steel. Stainless steel electrode:
- 16. Hardfacing on buffered specimen:
- 17. Parameter Reading Rotation speed meter 0.42 RPM Powder speed 11.6 gm/min Voltmeter reading 29 V Ammeter reading 130A Powder gas 4.3 LPM Centre Gas 5LPM Observations for Hardfacing on buffered specimen:
- 18. CONCLUSION
- 19. Sr. No. Parameter Conventional method Modified method 1 Rotation speed meter 0.42 RPM 0.42 RPM 2 Powder speed 11.6 gm/min 11.6 gm/min 3 Voltmeter 19.6 V 29 V 4 Ammeter 120 A 130 A 5 Powder gas 3.7 LPM 4.3 LPM 6 Centre Gas 2.6 LPM 5LPM Comparison Between Conversional welding and Hardfacing after Buffering process: