Final machining After cooling, machine to correct tolerances, use

3.01 171

1. Machine preparation Align the spindle in a lathe and turn a suitably wide and

deep groove in the hardened face to remove all stellite down to clean, pure base material Make room for at least two layers of weld metal.

2. Weld preparation Welding should as far as possible be carried

out in the horizontal position. A suitable jig should be prepared, holding the spindle in a tilted position allowing it to be rotated.

3. Preheating Preheat the valve head evenly to 50–00 °C and

maintain during welding. Preheating tempera- ture depending on type of alloy in valve.

4. Welding Electrodes should be dried at 50 °C for 1 hour

prior to use. The Unitor miniheater electrode quiver may be used for this. Keep the arc short and hold the electrode as near as possible to 90°C to the work piece. Welding with IMPACT-39 S does not require any other electrode. In order to minimise heat effects, the welding should be done in stages. Place the first bead towards the outer side of the groove, and do about one third of the circumference. Then start at the oppsosite side and do the second bead so it finishes where the first one started. Finally do the third, starting where the first one finished. For large diameter spin- dles the bead should be done in four parts. Grind the starting and stopping point of each bead. Also grind the bead itself to remove possible slag and spatter, in order to obtain a smooth transition between beads. Control the temperature adjacent to the welding zones and do not start the next bead until the base metal has regained the correct temperature.

5. Cooling When the top layer is completed, the spindle

should be immersed in insulating material or dry sand in order to ensure slow cooling.

6. Final machining After cooling, machine to correct tolerances, use

toolbit quality H1 or K10 with negative 4° cutting angle, low turning speed and fine feeding. Suggested jig for holding spindles. Large diameters Small diameters Welding bead sequence Ensure slow cooling. Put the first bead towards the outer side of the groove Second layer or top layer First layer or buffer layer Note: Each layer can consist of several beads 3.01 17 Electrode for Joining Wear Resistant Overlays Identification: Classifications Approvals Type of current Welding positions Materials to be welded All weld metal composition Typical mech. properties of weld metal Packaging data Welding data AC DC+ PA PB PC PF .5mm only PE, PD Repair of: Worn winch wheels and anchor windlass wheels on anchoring systems. Cargo handling equipment and dredger equipment, T1-steel, N-A-xtra steel, OxAR steel, Fine grain steel, Cr Mo steel, Manganese steel, Shear blades. Trawler equipment subject to metal to earth wear and metal to metal wear. Suitable for both joining and making wear resistant overlays. N.A. Imprint Unitor WEARMAx-37 AWS A5.4 ~ E 307-6 Fe Cr Ni Mo Mn Si Rest 16–0 7–10 1.3–.3 5–7 1 Max Diameter Length Electrodes Net weight Product No. Boxes mm. mm. per box per box per box per carton .5 350 49 1.6 095-606454 6 3. 350 68 3.5 095-606455 3 4 350 4 3.4 095-606456 3 Re-drying temperature: 50 °C 48 °F for one hour. Tensile Yield Elengation Hardness as Hardness Recovery strength strength welded HB after work MPa MPa hardening HB 650-700 480-530 30–40 190 415 150 Diameter Current Arc time Deposition rate Electrodes per Fume class mm. range, A electrode, sec. Kgh kg weld metal Danish Std. .5 75–140 80 0.9 48 6 3. 90–170 103 1. 31 6 4 10–40 105 1.8 1 7 MSDS available on request. 3.01 173 Unitor WEARMAx-37 is an electrode which produces a stainless deposit with excellent resistance against wear. The initial weld deposit is com- paratively soft with high elongation. When subjected to grinding, machin- ing or wear, the surface will harden to more than 400 HB providing a smooth hard and crack resistant layer with low coefficient of friction. This produces a surface, which despite being tough, does not cause wear on matching parts, like chain wires etc. The electrode is also designed to achieve high tensile strength and yield properties, making it an excel- lent electrode for joining dissimilar metals. Areas of application: Anchor winch wheels and guides, windlasses drums and rollers, cranes and track wheels, sprocket wheels. Also used for joining Cr Mo steel, T1-steel, Manganese steel, N-A-xtra steel, OxAR steel, HARDOx 400, fine grain steel and shear blades. Special publication ID.No. 11051 WEARMAX 327 Available Winch wheel Chain 3.01 174 Electrode for Wear Resistant Overlays Identification: Classifications Approvals Type of current Welding positions Materials to be welded All weld metal composition Typical mech. properties of weld metal Packaging data Welding data AC DC+ PA PB PC Hardsurfacing of: Austenitic manganese steel with 1–14 Mn Harden able or self harden able steel N.A. Imprint Unitor ABRATECH-330 DIN 8555 E 10-UM-60-G Fe Cr Mn Si C Rest 31 0. 1.3 3.5 Diameter Length Electrodes Net weight Product No. Boxes mm. mm. per box per box per box per carton 3. 350 68 3.5 095-7575 3 4.0 350 4 3.4 095-7583 3 Re-drying temperature: 50 °C 48 °F for two hours. Hardness Recovery HRC 57-6 170 Diameter Current Arc time Deposition rate Electrodes per Fume class mm. range, A electrode, sec. Kgh kg weld metal Danish Std. 3, 100-150 95 1.34 8.3 6 4,0 130-180 98 1.91 19.1 6 MSDS available on request. 3.01 175 General Information Unitor Abratech-330 is a hard sur- facing electrode with excellent resistance to abrasive wear under moderate impact and pressure. The electrode deposit carbides in an aus- tenitic matrix. Edge preparation: Left over of previ- ous welds should be removed using the gouging electrode CH-- 38 Pre-heating: Depends on steels car- bon equivalent Ce and the shape and size of part to be welded. We recommend as follows: Ce 0, No need for pre-heating Ce 0,-0,4 Pre-heat to 100–00°C Ce 0,4-0,8 Pre-heat to 00–300°C Austenitic Manganese steel must not be pre-heated. The interpass temper- ature of object not to exceed 50°C. When welding Austenitic Manganese steel with 1–14 Mn it is an advan- tage to make a buffer layer with Wearmax-37. When welding on harden able or self harden able steels it is an advantage to make a buffer layer with Tensile- 38 N. Weld using DC+ polarity and keep electrode angle close to 90°and with a short arc. A small weaving motion from side to side might be employed. Normally the required hardness is obtained in one layer. Alternative welding: Alternative A Large massive work pieces Ø 3, mm = 130–150 A Ø 4,0 mm = 150–180 A Alternative B Smaller items with less volume and where interpass temperature is criti- cal Ø 3, mm = 100–10 A Ø 4,0 mm = 130–140 A The electrode should be re-dried to 50° C for two hours before use Remove old welds using gouging electrode CH-2-382 Max interpass temperature when welding Austenitic manganese steel should be 250 °C Buffer layer on Austenitic manganese steel is done using Wearmax-327 ←฀ Abratech-330 ←฀ Wearmax-327 ←฀ Abratech-330 ←฀ Tensile-328N Buffer layer on harden able or self harden able steels is done using Tensile-328 N The effect of dilution with base material is decreased when the welding seams are placed as above Max 250 °C 3.01 176 Electrode for Stainless Steel Identification: Classifications Approvals Type of current Welding positions Materials to be welded All weld metal composition Typical mech. properties of weld metal Packaging data Welding data Imprint Unitor 188-31 N 316L-17 SFAAWS A5.4 EN 1600 E 316L-17 E 19 1 3 LR 1 DNV GL LR BV ABS 316L 4571 316L 316L E 316L 17 Diameter Length Electrodes Net weight Product No. Boxes mm. mm. per box per box per box per carton 1.6 300 13 1.6 095-699397 6 .5 300 89 1.7 095-699405 6 3. 350 54 1.7 095-699413 6 Re-drying temperature: 350 °C 66 °F for two hours. Diameter Current Arc time Deposition rate Electrodes per Fume class mm. range, A electrode, sec. Kgh kg weld metal Danish Std. 1.6 30–45 6 0.6 30 3 .5 45–90 35 1.1 97 4 3. 60–135 46 1.4 56 4 MSDS available on request. 90 of max. amperage Tensile strength Yield strength Elongation Impact value MPa MPa ISO-V J 570 460 40 At +0°C = 60 At –0°C = 55 C Mn Si Cr Ni Mo FN max. 0.030 0.5 - 1. max. 0.9 17.0 - 19.0 11.0 - 13.0 .5 - 3.0 3–10 AC DC+ PA PB PC PF PE, PD Steel grades BS 970 DIN 1744017445 W.Nr. AFNOR NF A35- ASTMACI SIS UNS 1554 573574576582 A240, A312, A351 Extra low 316S11 xCrNiMo1713 1.4404 ZCND17.1 TP 316L 353 S31603 carbon CF-3M J9800 C0.03 316S13 xCrNiMo18143 1.4435 xCrNiMoN171 1.4406 ZCND17.1 á l’N TP 316LN S31653 xCrNiMoN17133 1.449 ZCND17.13 á l’N Medium 316S31 x5CrNiMo171 1.4401 Z6CND17.11 316 TP 316 347 S31600 carbon 316S33 x5CrNiMo17133 1.4436 Z6CND17.1 343 S30409 C0.03 316S33 G-x6CrNiMo181 1.4437 Z6CND17.1 C P F-8M J9900 316S33 G-x10CrNiMo189 1.4410 316S33 G-x6CrNiMo1810 1.4408 Z6CND17.1 C P F-8M J9900 Ti-Nb 30S31 G-x6CrNiMoTi171 1.4571 Z6CNDT17.1 316Ti 344 S3100 stabilized S31635 347S31 Z6CNNb17.1 TP 347 338 S34700S34709 347S31 x6CrNiNb1810 1.4550 Z6CNNb17.1 TP 347 338 S34700S34709 347S31 G-x5CrNiNb189 1.455 Z6CNNb18.10 CF-8C, CPF-8C J9710 LMA Electrode 3.01 177 Unitor 188-31 N is a rutile basic type electrode for welding stainless and acid resistant steel containing 16–18 chromium, 10–14 nickel and –3 molybdenum. It is suitable for all welding positions. When welding tanks containing cor- rosive elements, it must be remem- bered that the final bead must be laid on the side exposed to corrosion, to prevent intercrystalline corrosion. The electrode will operate on AC or DC polarity. It is always preferable to use DC positive when welding stainless or acid-resistant steel. Use a brush with stainless steel wire bristles when cleaning up the weld. If an ordinary wire brush is used, iron oxides will be deposited in scratches left by the brush, as this can lead to corrosion. The dark oxide deposit formed on either side of the bead should also be removed. Best result is obtained using Unitor Pickling Gel to remove discolouration and oxides after welding. For welding stainless acid-resitant steel to low alloy steel, use Unitor electrode 314-3 N. Welding: 1. Use a short arc. A long arc will increase arc tension, resulting in lower current output and poor fusion.

2. The electrode should be held