Universal Wear Solutions Package Welding Instructions

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Table of Contents

ESCO Welding Instructions for Universal Wear Solutions Package

Safety 3

Introduction 4

ESCOALLOY™ Plate 4

Infinity™ Bi-Metallic Buttons, Blocks, Bars and Runners 5

Infinity Overlay Plate Fabrication 6

Infinity Cast Wear Tiles 8

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Safety and Warnings

General/Safety InformationThe safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures.

Signal WordsThroughout this manual are statements preceded by a special attention symbol: The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury.

WARNING: A statement preceded by “WARNING” is information that should be acted upon to prevent serious injury.

CAUTION: A statement preceded by “CAUTION” is information that should be acted upon to prevent equipment damage.

An additional signal word that is not preceded by the attention symbol is:

IMPORTANT: A statement preceded by the word “IMPORTANT” is information that possesses special significance.

Personal SafetyWARNING: When performing the work described in these instructions, always work safely and use proper safety

equipment to help avoid injury. All persons performing maintenance work should wear OSHA- approved hard hat, safety glasses, steel-toed shoes, and gloves.

WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHA-approved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way.

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IntroductionThe instructions contained in this manual are the recommended procedures for installing ESCO Universal Wear Solutions products. The products include ESCOALLOY™ Plate and the full family of Infinity™ Bi-Metallic Products: Buttons, Blocks, Bars, Runners, Wear Tiles, and Chromium Carbide Overlay Plate.

For additional information on Universal Wear Solution Products, please refer to product specific instructions provided by ESCO or contact your ESCO representative.

ESCOALLOY Plate

Welding

Recommended Electrodes

When welding to low alloy steel When welding to Manganese

Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16

Gas Metal Arc Welding (GMAW) E70S EC309 or ER309

Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M(dual shield) E309T-1

Preparation

ESCOALLOY 400 and ESCOALLOY 500 plate may be welded using conventional, low hydrogen welding processes. IMPORTANT: To properly control moisture, electrodes that have been exposed to the air for more than one hour or were not stored in an airtight container should be baked in a ventilated oven at 260°C/500°F for two hours prior to use. After baking, the electrodes can be stored in a ventilated holding oven at 65°C/150°F. Remove only one hour’s supply at a time.

Recommended Minimum Preheat Temperatures

ESCOALLOY 400 to Plate

ESCOALLOY 500 to Plate

Plate to CastingPlate to

Manganese

Up to 25mm/1in Sections 20°C/70°F 95°C/200°FFollow preheat

requirements for the casting alloy

Do not preheat25mm/1in to 51mm/2in 65°C/150°F 120°C/250°F

Over 51mm/2in 120°C/250°F 175°C/350°F

Welding Procedure

When welding, use short stringer beads and remove slag after each pass. Interpass temperature should be kept below 260°C/500°F for low alloy steel, and below 120°C/250°F for Manganese Steel. However, for fabrications involving both castings and plate components, preheat and interpass temperature requirements for the casting shall take precedence. Post weld heat treatment should not be applied if original hardness levels are to be maintained.

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Infinity™ Bi-Metallic Buttons, Blocks, Bars and Runners

Welding

Recommended ElectrodesWhen welding to low alloy steel When welding to Manganese

Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16Gas Metal Arc Welding (GMAW) E70S EC309 or ER309Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M(dual shield) E309T-1

Preparation

Prior to welding, remove all slag and scale from the surface to be welded. To ensure maximum weld strength, the surface should be clean and as flat as possible.

CAUTION: DO NOT preheat Infinity Bi-Metallic Buttons, Blocks, Bars or Runners. Preheat may be necessary for the parent metal only. For heavy sections (greater than 40mm/1.50in), the following minimum preheat temperatures should be used. No preheat is required for Manganese Steel.

Working Temperature > 5°C/40°F: 95°C/200°F Working Temperature ≤ 5°C/40°F: 175°C/350°F to 205°C/400°F

Welding Procedure

IMPORTANT: Welds should not come in contact with the Chrome White Iron (CWI) section. A minimum gap of 2mm/.06in should be maintained. Failure to do so could result in cracking.

For best results, the bi-metallic button or block should be clamped and tack welded into position prior to final welding. To minimize heat input, maximum run lengths should be 50mm/2.00in to 70mm/2.50in. Continuous welds should not be used.

Interpass temperature should be kept below 260°C/500°F for Low alloy steel, and below 120°C/250°F for Manganese Steel. The parent metal should only be warm to the hand 150mm/6.00in from the weld. No post heat is required.

CWI

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Infinity™ Overlay Plate Fabrication

Cutting

The recommended method for cutting overlay plate is Plasma Arc. Cut from the mild steel side. Cutting from the overlay side will deposit carbides on the mild steel which, unless ground off, can cause the weld to fail. An abrasive saw with a silicon carbide wheel, while slow, is also a viable option. If neither of these processes is available, carbon arc cutting can be used. However, due to the inaccuracies and extensive clean up involved, this is not the preferred method.

Welding

Recommended ElectrodesWhen welding to mild steel When welding to dissimilar metal

Shielded Metal Arc Welding (SMAW) E7018 E309-16Gas Metal Arc Welding (GMAW) E70S-X EC309 or ER309Flux Cored Arc Welding (FCAW) E70T or E71T E309T-1

Attachment Methods

Prior to welding, remove all slag and scale from the surfaces to be welded. Preheating of the overlay plate is not required, but preheat requirements for the parent material should still be followed.

IMPORTANT: Attachment welds should not come in contact with the overlay material. Failure to follow this could result in cracking. Additionally, the overlay material has no structural strength, and therefore should not have anything welded to it.

Fillet WeldRemove slag and scale from the area to be welded. Leave a 2mm/.06in gap between the fillet weld and the overlay material as shown to the right. This will help prevent cracking.

Plug WeldRecommended plug weld size is 25mm/1.00in x 76mm/3.00in spaced every 381mm/15.00in to 610mm/24.00in. Slag and scale should be removed, and there should be a 2mm/.06in gap between the weld and overlay material as shown to the right.

StudsMinimum recommended stud size is 10mm/0.38in. Special care should be taken when welding studs onto thinner backing plates to avoid potential burn through.

IMPORTANT: Studs can ONLY be attached to the mild steel side.

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BoltsThe chromium carbide overlay is too hard and brittle to machine using traditional methods. To get around this, a machined mild steel insert is welded into a precut hole. The minimum recommended bolt size is 10mm/0.38in. Countersunk holes can also be cut directly using spark erosion.

Butt JointsAfter removing slag and scale from the weld surface, bevel the edge leaving a 3mm/.13in land. When welding the sections together, care must be taken to avoid burning through the mild steel. The gap in the overlay material can be filled with overlay weld. In applications where the overlay material side cannot be reached, like in a pipe, a root pass should be made with austenitic stainless steel rod. This will ensure that the subsequent welds will not come in contact with the hardfacing, thus reducing the risk of the weld cracking.

Special Application Welding

The standard welding procedures described above may be insufficient in applications where a thinner mild steel backing plates (6mm/.25in or less) is attached to something that experiences a lot of flexing, like a dragline bucket. In these special applications, the following welding procedure may be used.

Recommended Electrodes Recommended Shield Gas

Shielded Metal Arc Welding (SMAW) E309-16 n/a

Gas Metal Arc Welding (GMAW) EC309 or ER309 98%Argon + 2%Oxygen

Flux Cored Arc Welding (FCAW) E309T-1Follow wire manufacturer’s

recommendations

Fillet/Plug Weld:Remove slag and scale from the area to be welded. Use the stainless steel material as recommended above. Apply a fillet weld the full height of the plate as shown to the right

Overlay weld (optional)

Austenitic stainless steel rod weld (optional)

Austenitic stainless

steel weld

Machined insert

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Additional Overlay Protection

The low hydrogen weld material is much more vulnerable to abrasion than overlay material, and may prematurely wear. To avoid this, plug welds, fillets, and joints welded with low hydrogen rod located in abrasive areas can have overlay material applied. Overlay material can also be applied to gaps between overlay plate and bolt heads to protect against wear. A list of compatible electrodes is below.

Manual Electrode Semi-Automatic Electrode

Lincoln Wearshield 60 Lincore 60-0

Stoody Coated Tube Stoodite 2134 100HC, 101HC, 0, G

McKay Hardalloy 55 255-0

Alloy Rods 40 40

Bohler Fox dur 65 Fox dur 650KS

Eutectic N6006 -

Rankin 4 H

Stellite Delchrome 94 100-0

Amsco Superchrome Superchrome S/A

Sodel Sodel 2024 Sodel 8240

Using the manufacturer’s recommended amperage setting, the overlay material can be applied using either a weave or stringer method. If possible, it is recommended to apply two overlay layers. Preheating to 190°C/375°F to 205°C/400°F is necessary when welding to castings or alloy plate.

Infinity™ Cast Wear Tiles

Welding

Recommended Electrodes

When welding to low alloy steel When welding to Manganese

Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16

Gas Metal Arc Welding (GMAW) E70S EC309 or ER309

Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M(dual shield) E309T-1

Preparation

Prior to welding, remove all slag and scale from the surface to be welded. To ensure maximum weld strength, the surface should be clean and as flat as possible.

CAUTION: DO NOT preheat Infinity Cast Wear Tiles. Preheat may be necessary for the parent metal only. For heavy sections (greater than 40mm/1.50in), the following minimum preheat temperatures should be used. Manganese Steel should not be preheated.

Working Temperature > 5°C/40°F: 95°C/200°F Working Temperature ≤ 5°C/40°F: 175°C/350°F to 205°C/400°F

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Welding Procedure

IMPORTANT: Welds should not come in contact with the Chrome White Iron (CWI) section. A minimum gap of 2mm/.06in should be maintained. Failure to do so could result in cracking.

For best results, the Cast Wear Tile should be clamped and tack welded into position prior to final welding. To minimize heat input, maximum run lengths should be 50mm/2.00in to 70mm/2.50in. Continuous welds should not be used.

Interpass temperature should be kept below 260°C/500°F for low alloy steel, and below 120°C/250°F for Manganese Steel. The parent metal should only be warm to the hand 150mm/6.00in from the weld. No post heat is required.

Standard Wear Tiles

Jacketed Wear Tiles

CWI

CWI

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