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B S W A N T I W E A R T E C H N OL O G Y

THERMAL (COAL) POWER


STATIONS
WELDING REPAIR AND MAINTENANCE APPLICATIONS

ANTI WEAR TECHNOLOGY


Expensive equipment and industrial installations are
subject to daily attack by abrasion, corrosion, erosion,
wear and tear creating enormous costs to industries.
The application and use of our anti-wear product range
consisting of welding and brazing alloys, thermal spray
powders ,wear resistant plates and cold repair compounds
can increase the service life of vital machinery and parts
dramatically.

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BSW REPAIR APPLICATIONS

INDEX
PART

PAGE

PART

PAGE

Anti wear plates

11

Gearbox housing

Austenitic manganese steel

Grooving

Arms

Gouging

Augers

15

Hammers

Bearing housing

Hammer mill crusher

Boiler tubes

13

Idlers

Bucket

Impellors

13

Bucket teeth

Jaw crusher

Cast-iron housing

Metal preparation

Cast steel welding

10

Nickel alloy electrode

Chassis

10

Pump housing

Coal Grinding Roll

10

Pump shaft

12

Coal handling equipment

3/4

Rotor shaft

12

Coal Pactor

Screw

15

Coal Pulverizing Roll

10

Shafts

12

Clinker grinding roll

10

Sprocket

Conveyor screw

15

Super heater tubes

13

Crane

Tube bend

13

Crusher Hammer

Tube protection

13

Crusher Jaw

Thermal spray coating

13

Crusher rotor

Tungsten Carbide Hard


facing rod

15

Crusher shaft

12

Truck pads

Dozer blades

Valves

14

Extruders

15

Wear Plates

11

Exhaust fan

11

Fan blades

11

Worms

15

Flame brazing

15

Frames

Gears

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BSW REPAIR APPLICATIONS

COAL HANDLING EQUIPMENT

Machine: Excavator/Bulldozer
Part: Buckets/Dozer blades
Basematerial:Un/low alloy steel
Problem:
Wear on bucket and bucket teeth due to abrasion ,friction and impact by coal, sand, stone etc.
Equipment looses efficiency, causing increase in
operating costs.

Recommended Solution:
Protect bucket lips, sides and other wear areas by
applying a wear resistant high alloy Chromium
Carbide material.
Welding process: SMAW (stick electrodes)

Welding material: A) Gold 750


B) Gold 760
Use Gold 760 for severe abrasion
Welding process: GMAW( Wire welding)
Welding material: A) 750 MF/OA
B) 760 MF/OA
MF Wire (gas shielded)
OA Wire (no gas required)
BUCKET TEETH:
Base material: Austenitic Manganese steel/Cast steel
Welding Process: SMAW (stick electrodes)
Use this welding method for rocky conditions

Use this method for sandy or clay conditions

1) Use Gold 740 (HMN) for rebuilding if teeth are


badly worn.
2) Use gold 730 for points (edge)
3) Use Gold 750 to protect top and sides
4) Use gold 760 for severe abrasion
All the above alloys are also available as
Flux cored wires for GWAW (MIG/MAG)
Or open arc welding.

BENEFIT:
prolong lifetime of equipment up to 300 %
Increase efficiency, reduce power consumption

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BSW ANTI WEAR


TECHNOLOGY

COAL HANDLING EQUIPMENT/REPAIR

BUCKET TEETH:
Base material: Austenitic Manganese steel/Cast steel
Problem: teeth heavily worn
Solution: Cut spring steel to size and weld to worn teeth using Stick electrode or Wire

Product: Gold 320 or 320 MF (FCAW)


Repairing of cracks in coal/earthmoving
equipment.
Parts: Arms/Booms/Buckets/ Frames/Chassis
Base material: Cast steel/low alloy steel
Problem:cracked due to heavy loads
The above named parts are subject to heavy loads and
cracks can appear after some time.
We offer special high alloy/high strength filler
Materials allowing maintenance engineers and welders
to repair such cracked parts therefore achieving great
savings.

The following filler materials have proven most


successful in service.
1) Gold 330 a high strength (800 N) welding electrode
suitable for welding most types of steels. Gold 330 is
recommended for repairs on sections of up to 20 mm
thickness
2) Gold 320 is a austenitic Chrome,Nickel manganese
electrode with a high elongation and suitable for joining medium to thick sections.gold 320 can also be
combined with 330.a good method is to use gold 330
as base layer to achieve high strength and then fill up
the joint with gold 320
3) Gold 510 and 520 are the top products for all joining
repairs requiring highest strength and security.510 and
520 are Ni based alloys providing weld repairs of unmatched strength and security.

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BSW REPAIR APPLICATIONS

Rebuilding/Hard facing Track pads/Track rollers/Idlers


Machine: Crane
Part: Track pads
Basematerial:low alloy cast steel
Problem:
Wear on truck pads due to friction and pressure.
Equipment looses efficiency, causing increase in operating
costs.

Truck pads worn :


Solution :
Rebuild worn pads by surface welding.
Welding process: SMAW (stick electrodes)

Welding material: A) Gold 710


B) Gold 740
Use Gold 740 for longest lasting results
Welding process: GMAW( Wire welding)
Welding material: A) 710 MF/OA
B) 740 MF/OA
TRACKROLLER/IDLER REBUILDING
WORN TRACK ROLLER
Base material: Carbon steel
Track rollers and Idlers are subject to extreme
friction and pressure causing the parts to wear out
and become damaged.
Our weld repair solution:
Welding process: SMAW (stick electrodes)
Welding material: A) Gold 710
B) Gold 740
Use Gold 740 for longest lasting results
Welding process: GMAW( Wire welding)
Welding material: A) 710 MF/OA
B) 740 MF/OA

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BSW ANTI WEAR TECHNOLOGY

GEAR/SPROCKET REPAIRS BY WELDING/SURFACING


SAVING TIME AND MONEY BY REPAIRING GEARS

Gear teeth broken

By using the right technique and the right filler material


large savings can be achieved.
There are many shapes, sizes and materials in use today.
The choice of welding process will depend on availability of
Equipment and/or size of gear to be repaired.
Depending on the base material of the gear the following
materials have proven successful.

Gear repaired with gold 710

Base material Low alloy steel


Welding process: SMAW (Stick)
1) Gold 710 (HB 40) low alloy
2) Gold 330 (High Chrome alloy) for best results
3) Gold 620 ( Manganese bronze alloy)
Base material High alloy steel
Welding process: SMAW (Stick)
1 ) Gold 330 (High Chrome alloy) for best results
2) Gold 620 ( Manganese bronze alloy)
3) Gold 720 ( High speed steel alloy HRC60)
Base material Cast Iron:
Welding process: SMAW (Stick)
1) Gold 420 (Ni Fe Alloy)
2) Gold 720 (( Manganese bronze alloy)
All the above recommended Filler materials are also available as
TIG Rods for TIG Welding

Hard facing of Gears:

Head sprocket (coal mining )

To improve the lifecycle of certain gears the application of hard


facing alloys such as Gold 720 (high speed steel) and Gold 750
Chromium Carbide has proved successful.

Welding Tips:
Asses Analysis of base metal
Choose suitable filler material
Preheat accordingly.
Consider type of wear (metal/metal etc)

Rebuild Idler

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BSW REPAIR
JAW CRUSHERS
Are used to crush (reduce) hard materials such as coal,
stone etc.
The materials are crushed between Crusher Jaw plates
normally made form a wear resistant Manganese steel.
The high impact and compression causes the Jaw
plates to wear out and the crusher looses crushing
efficiency.
Replacement of crusher Jaw plates is often difficult,
time consuming and new jaw plates are expensive.

CRUSHER JAW PLATE


Base material; austenitic manganese steel.

Problem:Damaged (wear) by impact and compression


Solution: Weld repair
Rebuild worn sections using a impact and pressure resistant Manganese alloy.
For maximum wear resistance apply one top of a wear
resistant Chromium carbide alloy

Welding process: SMAW (stick electrodes)


Welding material: A) Gold 740 (HMN)
B) Gold 750 (HB63 )
C) Gold 760 (HB 65)
Welding process: GMAW( Wire welding)
Filler material: A) 740 MF/OA
B) 750 MF/OA
Welding Recommendations:
Keep jaws cool by partially submerging them in water.
Apply skip welding technique. keep temperature of jaw
below 200 C during repair. Rebuild worn section with
gold 740 a work hardening material. Apply on generous
pass to the peak of each corrugation.
Allow each bead to cool and check progress before applying next bead
Jaws will normally show some warpage after welding.
Straighten them in a press or clamp them prior to welding,
WE ALSO SUPPLY NEW CRUSHER JAW PLATES
Made from high quality Austenitic Manganese steel.
Sizes to clients specifications

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BSW ANTI WEAR TECHNOLOGY

HAMMER MILL CRUSHER


(COAL PACTORS )
widely used crusher system
With high reduction ratios,
used to crush materials such as coking coals.
limestone etc.

Problem:
The Hammers crushing the raw materials are
subject to extreme impact/pressure and abrasion and tend to suffer wear and tear making
the crusher machine inefficient.
Depending on the application such hammers
can be made from austenitic manganese steel
or low alloy cast steel.
EXAMPLE OF WORN CRUSHER HAMMER
SOLUTION and Recommendation.
1) increase lifetime(2-4times) of crusher by
applying 1 to 2 layers of gold 750 on new
hammers. Apply to wear areas.
2) Rebuild worn hammers by using one of the
following Welding materials.
A) Gold 710 a low alloy low cost electrode for
restoring dimension (within 2 layers and
thereafter apply 2 layers of gold 750 or 760
for maximum protection
B) Gold 740
for rebuilding and hardfacing.740 is a austenitic high alloy electrode and will provide best
long term result.
For best resistance use 750 or 760 as a
top layer.
All the above mentioned products are also
available for semiautomatic welding.
(FCAW) gas shielded or open arc

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BSW REPAIR APPLICATIONS

Products for repairing of Pump/Bearing housings.


CORROSION AND WEAR ON PUMPHOUSING.
Base material: wear resistant Cast iron.
Difficult to weld, as material is hard and tends to
crack when heat is applied.

Solution: Use BSW CRC 5 a epoxy base polymer


material which cab be applied without heat or pressure and is resistant to wear and corrosion.
Wear on Cast Iron Bearing housings
Use Gold 410/420 a Nickel based Welding electrode
for rebuilding.
Can be welded at low amperages (low heat input)
Easy machinable.

Cracked Gear box housing .


Base material Cast Iron.
Use Gold 110 to prepare (open) cracks for welding.
Then use Gold 410 or 420 to repair/join cracks.
Apply low heat technique (lo amperage) and skip
welding.

GOLD 110 FOR METAL PREPERATION


A use full product for gouging, cutting and piercing of cast iron steel and nickel alloys.
Easy to use no special equipment or training
needed, does not require compressed air or oxygen.

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BSW REPAIR APPLICATIONS

PRODUCTS FOR REPAIR OF COAL/CLINKER/ CRUSHING/


GRINDING EQUIPMENT
PART: CLINKER GRINDER ROLL
BASE METAL: Austenitic Manganese Steel
PROBLEM: Wear on Teeth and Body due to extreme
abrasion from clinker:

Solution: Weld repair


Rebuild worn sections using a impact and pressure
resistant Manganese alloy Gold 740
For maximum wear resistance apply one top of a
wear resistant Chromium carbide alloy
(GOLD 750)
Welding process: SMAW (stick electrodes)
Welding material: A) Gold 740 (build up)
B) Gold 750 /760 (top layer)
PART: COAL PUVERIZING ROLL
BASE METAL: Cast Steel
PROBLEM:
Cracking/spalling due to heavy pressure and impact
SOLUTION: Weld repair
Welding process: SMAW (stick electrodes)
Welding material: A) Gold 110 (to remove old metal)
B) Gold 320 (for build up)
C) Gold 740 (top layer)
BENEFIT:
Large saving in down time and money for new part

PART: COAL GRINDING ROLL


BASE METAL: High alloy Cast Steel
PROBLEM: heavy abrasion from coal causes roller
to wear down quickly resulting in material loss.
SOLUTION: Weld repair
Welding process: FCAW (Flux cored Wire welding)
Welding material: A) 740 MF WIRE (Build Up)
B) 750 MF WIRE ( Top Layer)
BENEFIT:
Increase in lifetime and repair cost are only a fraction
of new part

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BSW ANTI WEAR TECHNOLOGY

PRODUCTS FOR REPAIR OF EXHAUST FAN


EROSION /ABRASION ON FAN BLADES

Part: Fan blades


Base metal: low alloy steel
Exhauster fans in thermal power stations are subject to
extreme wear through erosion and abrasion by fly ash .
Solution A:
Anti Wear Protection by SMAW(MMA) Welding:
Rebuild and protect wear sections with one of the following electrodes.
1) GOLD 710 economy type electrode (HV 350)
2) GOLD 740 manganese type electrode
3) GOLD 750 chrome carbide electrode for best wear
resistance
Anti Wear Protection by thermal spray/brazing:
Rebuild and protect fan blades by using the spray fuse
process which offer maximum wear resistance
1)POWDER: 2060 SF a nickel chromium alloy (HRC60)
2) POWDER: 2070 SF a nickel tungsten alloy
Apply a coating of approx 1 mm thickness
If more build up or thicker deposits are required apply
GOLD 788 GT (to be applied by Brazing )

Anti Wear Protection by Anti Wear Plates (AWP) ;


If Blades are heavily worn (to thin) a weld repair may not
be economical or not possible. In such a case the application of our Anti wear plates may be the best solution.
Choose one of the following types.
1) 750 AWP a chromium carbon plate (HRC 58-62)
2) 2070 AWP a powder coated (NIWC) plate for highest
wear resistance
Whatever your wear problem we have a solution

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BSW REPAIR APPLICATIONS

SAVING TIME AND MONEY WITH SHAFT REPAIRS


1)
2)
3)
4)
5)
6)
7)

Axle shafts
Cam shafts
Crank shafts
Drive shafts
Crusher shafts
Pump shafts
Rotor shafts

With our material you can repair them


and make them last longer.
Shafts are mostly made from low alloy heat treatable
steels.
However in the case of pump shafts high alloy stainless
steels or nickel alloy are also used.
Shafts are subject to metal/ metal friction and are showing wear after some time in operation.
New shafts can be expensive and are not always readily
available.
By the method of repair welding or spraying such valuable
shafts can be easily and quickly repaired.
The following products have proven successful for shaft
repair.
1) Welding process: GMAW(MMA)
A) Gold 330 high alloy Cr Ni.type electrode
B) Gold 620 high alloy bronze type electrode
2) Welding process: FCAW( MIG/MAG)
A) 330- MF fluxcored CrNi wire
B) 620-MF gas shielded bronze alloy wire
3) Thermal Cold spray system( Unispray)
Powder: 2021-CS (BONDLAYER)
2400-CS ( chrome alloy coating)

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BSW ANTI WEAR TECHNOLOGY

PRODUCTS FOR REPAIRS OF PUMP IMPELLORS/VALVES


Impellor damaged by erosion

Part: Impellor
Base metal: stainless steel
Pump impellors in thermal power stations are subject to
extreme wear through erosion, corrosion and abrasion .
Solution A.
Anti Wear Protection by SMAW(MMA) Welding:
Rebuild and protect wear sections with one of the following electrodes.
1) GOLD 330 special chrome nickel alloy electrode.
2) GOLD 320 special chrome, nickel manganese alloy.
Part: Impellor
Base metal: Cast-Iron
Problem:
Pump impellors in thermal power stations are subject to
extreme wear through erosion, corrosion and abrasion .
Solution
Anti Wear Protection by SMAW(MMA) Welding:
Rebuild and protect wear sections with one of the following electrodes.
1) GOLD 410 special pure nickel alloy electrode.
2) GOLD 420 ferro nickel alloy electrode
3) use CRC 5 cold weld compound if material is to Difficult to weld (Ni Hard etc.)
Base metal: Tin Bronze
Use GOLD 620 (ALMN Bronze) or 907 tin bronze

Tube bends

Boiler tubes/ Super heater tubes/Heat exchanger tubes


Problem:
EROSION ON TUBE BENDS

Tubes and especially tube bends subject to erosion and tend to


wear out causing high expense in replacement and downtime.
Solution:

A) use thermal spray fuse process (gun 2010) and apply powder type 2060 SF (coat approx 1.5 mm thick)
TUBE PROTECTION
A) Use cold thermal spray process (UNISPRAY) and apply
Bond coat powder 2121 CS , followed by powder 2185CS

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BSW REPAIR APPLICATIONS

PRODUCTS FOR REPAIR OF VALVES


CORRODED VALVE

Valves are subject to corrosion, cavitations, erosion and


often high temperature. This causes seat or body to wear
down and eventually going out of service.
With the following products Maintenance engineers are
able to repair and prolong the service life.
1) CAST-IRON VALVES (BODY)
For weld repairs on body or seat use GOLD 410 or 420
For cold repairs on difficult to weld Cast-Iron (Ni Hard)
we recommend the use of cold repair compounds such as
CRC 3 and CRC 5
2) STEEL/STAINLESS STEEL VALVES
for weld repairs on body or seats use GOLD 330 or 320
3) VALVES SUBJECT TO HIGH TEMPERATURE
AND GASES
for weld repairs on seats (cone) use GOLD 510 or 1045
1045 is available as Electrode( SMAW) TIG(GTAW) Rod
FCAW flux cored wire for semiautomatic welding or
as1045 PTA Powder for Plasma Arc welding
applications

VALVE AFTER MACHINING

VALVE HARDFACED WITH 1045 PTA POWDER

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BSW ANTI WEAR TECHNOLOGY

PRODUCTS FOR REPAIRING/HARDFACING SCREWS


AUGER HARDFACING WITH GOLD 750

CONVEYOR SCREWS/AUGERS/WORMS/
EXTRUDRES
are subject to abrasion by coal, sand, cement, waste etc
causing the part to wear out and loosing feeding efficiency
ANTI WEARPROTECTION BY SMAW (STICK) WELDING
If screw shows heavy wear and needs rebuilding use one of the following electrodes.
1) GOLD 330/320 a universal electrode for rebuilding
2) GOLD 750/760 for hardfacing the wear aerea (flight, shaft)
GOLD 750 is a highly resistant chromium carbon alloy offering
maximum resistance to mineral abrasion.
New screws can be made from low alloy steel and then
Hard faced with Gold 750 (HRC 58) or Gold 760 (HRC 63)
This is a low cost and efficient procedure.

Protect shaft (body) and flight with GOLD 750

Oxy-Fuel gas welding/brazing Hard surfacing procedure for screw protection


This technique is recommended when hard facing on thin sections of metal or on edges. (screws,)
The OFW method produces smooth, precise and extremely high
quality surfaces.
The OFW Process has a very low dilution(~ 5 %) and is therefore ideal when maximum hardness and abrasion resistance is of
prime importance.
This process also allows easy control over the weld deposit.
Most steel can be hard faced whit this method however it should
not be used on manganese steel and free machining steels.
OFW deposits provide greater wear resistance then GMA
overlays.

Hard facing Flame brazing

The distribution of the particles is more even and the possibility of


carbide dissolution is reduced.
TYPICAL PROVEN OFW PRODUCTS ARE
1) 780 GT TUBULAR TUNGSTEN GAS HADRFACING ROD
FOR MINERAL ABRASION
2) 788 GT FLEXIBLE ROD CONTAINING TUNGSTEN,NICKEL AND BORON FOR ABRASION AND EROSION
3) 900 GT NICKEL CHROME BORON ALLOY FOR ABRASION,CORROSION AND HEAT

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BSW ANTI WEAR TECHNOLOGY