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Indonesian Welding Society (IWS)

Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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.

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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


Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Factors influencing dilution


1.

Welding Seed (Slow speed

2.

Welding Polarity

3.

4.

DCEN Low Dilution

AC Intermediate Dilution

DCEP High Dilution

Dilution , High speed

Dilution )

Heat Input

Low HI Low Dilution

High HI High Dilution

Welding Technique

Stringer beads Low Dilution

Weave beads High Dilution


Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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
the base material.

USE AUSTENITE CONSUMABLE FOR


BUFFER LAYER

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Electrode for repair Cast Iron


1. Pure Nickel Type electrode
2. Nickel-iron type electrode
3. Nickel-cupper type electrode

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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

Indonesian Welding Society (IWS)

Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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% )

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Re-Build Crusher Hummer (OK 15.65) DIN 8555 composition


C 0.9%, Si 0.4%, Mn13%, Ni 3% Welding Process FCAW
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Hardfacing Teeth Exapator (OK 84.58) %C 0.7, Si 0.6%, Mn


0.7% & Cr 10%, welding process SMAW
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Hardfacing Tumbler (OK 84.84) %C 3.0, Si 2.0%, Cr 8.0%, V


6.0% & Ti 6.0%, welding process SMAW
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Repair Oil & Gas Drill Tools

Stabillizer drill tool, build up 304L powder and


Hardfacing Tungstent Carbide welding Process
PTAW
Indonesian Welding Society (IWS)

Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Repairing Drill Bit


Built up OK 83.28
(C 0.1% & Cr 3.2%)
Hardfacing

Before Repair

OK 84.84 (E 10-60GP)
Welding Process
SMAW

After Repair
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

Rail Repair

Mould Welding OK 74.74


Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

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
Indonesian Welding Society (IWS)
Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi

THANK YOU

Indonesian Welding Society (IWS)


Welding Engineering, Underwater Welding , Certification Personnel Welding and NDT Services
Jl. Bendungan Hilir Raya GII No.13. Jakarta 10210.Telp: 021-578 51840, Fax: 021-5712835
Email: sekretariat@api-iws.org

By Sabandi