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Universal Wear Solutions Product Welding Instructions

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IntroductionThe instructions contained in this manual are the recommended procedures for installing ESCO Universal Wear Solutions products. The products include ESCO AR plate and the full family of Infinity Bi-Metallic Products: But-tons, 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.

Table of Contents

Safety

General/Safety information 4

Signal Words 4

Personal Safety 4

ESCO AR Plate

Welding, Preparation, Welding Procedure 5

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

Welding, Preparation, Welding Procedure 6

Infinity Overlay Plate

Cutting, Welding, Attachment Methods, Fillet Weld, Plug Weld 7

Studs, Bolts, Butt Joints, Special Application Welding, Fillet/Plug Weld 8

Additional Overlay Protection 9

Infinity Cast Tiles

Welding, Preparation 9

Welding Procedure 10

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SafetyGeneral/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 machine or equipment damage.

Additional signal words that are not preceded by the attention symbol are:

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

Tip: A statement preceded by “Tip” is information that is handy to know and may make your job easier.

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

safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way.

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ESCO AR PlateWelding

WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way.

PreparationESCO AR 400 and ESCO AR 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.

Welding ProcedureWhen 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.

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-1 or E70S-6 EC309 or ER309Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M (dual shield) E309T-1

Recommended Minimum Preheat Temperatures

ESCO AR 400 to Plate ESCO AR 500 to Plate Plate to Casting Plate to Manganese

Up to 25mm / 1.00in. Sections 20°C / 70°F 95°C / 200°F Follow preheat requirements for the casting alloy

Do not preheat25mm / 1.00in. to 51mm / 2.00in. 65°C / 150°F 120°C / 250°FOver 51mm / 2.00in. 120°C / 250°F 175°C / 350°F

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PreparationPrior 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 Bimetallic 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

Welding ProcedureIMPORTANT: Welds should not come in contact with the Chrome White Iron (CWI) section. A minimum gap of 2mm/0.06in. should be maintained. Failure to do so could result in cracking.

For best results, the bimetallic button or block should be clamped and tack welded into position prior to final weld-ing. 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 when working with manganese steel. No post heat is required.

Infinity® Bimetallic Buttons, Blocks, Bars and RunnersWelding



CWI

Mild Steel

CORRECT INCORRECT2mm /0.06in.

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Infinity® Overlay PlateCutting 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

Attachment MethodsPrior 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 / 0.06in. 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 / 0.06in. gap between the weld and overlay material as shown to the right.


Recommended ElectrodesWhen welding to mild steel When welding to dissimilar metal

Shielded Metal Arc Welding (SMAW) E7018 E309-16Gas Metal Arc Welding (GMAW) E70S-1 or E70S-6 EC309 or ER309Flux Cored Arc Welding (FCAW) E70T or E71T E309T-1

CWI

Mild Steel

Fillet Weld

CORRECT INCORRECT2mm / 0.06in.

Mild Steel

Plug Weld

CORRECT INCORRECT

Overlay

Mild Steel

Overlay2mm / 0.06in.

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Infinity® Overlay Plate ContinuedStudsMinimum 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.

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 / 0.13in. 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 WeldingThe standard welding procedures described above may be insufficient in applications where a thinner mild steel backing plates (6mm / 0.25in. 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.

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

Mild Steel

Weld

Stud Weld

Stud

Overlay

Mild Steel

Weld

Machined insert

Overlay

Mild Steel

Overlay

Mild Steel

Weld

Overlay weld (optional)

Overlay

Mild Steel

3mm / 0.13in.

Austenitic stainless steel rod weld (optional)

Weld

Overlay

Mild Steel

Overlay

Mild Steel

Overlay

Mild Steel

Austenitic stainless

steel weld

Suitable when overlay with a thin mild steel backing (6mm/0.25in. or less) is used in an application where it experiences a lot of �exing.

Recommended Electrodes Recommended Shield GasShielded Metal Arc Welding (SMAW) E309-16 N/AGas Metal Arc Welding (GMAW) EC309 or ER309 98% Argon + 2% Oxygen

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

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Infinity® Overlay Plate ContinuedAdditional 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 ElectrodeLincoln Wear shield 60 Lincore 60-0Stoody Coated Tube Stoodite 2134 100HC, 101HC, 0, GMcKay Hard alloy 55 255-0Alloy Rods 40 40Bohler Fox dur 65 Fox dur 650KSEutectic N6006 -Rankin 4 HStellite Delchrome 94 100-0Amsco Superchrome Superchrome S/ASodel 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 is necessary when welding to castings or alloy plate.

Infinity® Cast Wear TilesWelding


PreparationPrior 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. Do not preheat manganese steel.

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



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Infinity® Cast Wear Tiles ContinuedWelding ProcedureIMPORTANT: Welds should not come in contact with the Chrome White Iron (CWI) section. A minimum gap of 2mm / 0.06in. 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.

CWI

Mild Steel

2mm / 0.06in.

Standard Wear Tiles

CORRECT INCORRECT

CWI

Mild Steel

2mm / 0.06in.

Jacketed Wear Tiles

CORRECT CORRECT

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