What Are the Most Common Remediation Techniques?

This book gives a concise description of the welding repair technology of damaged parts in engineering structures from the perspective of practicality. It strives to be concise and practical, and has a significance of guiding practice.

Welding repair technology

The book was welcomed by society and many readers after it was published in 2005. In addition to maintaining the original process characteristics and practicality of outstanding welding repair, reflecting the current application status of welding repair technology, and giving some application examples of welding repair of damaged parts of typical engineering structures, the second edition of this book also updates and supplements New application examples make it more suitable for practical applications. Added some new processes and successful experiences, citing a large number of examples of welding repair of various mechanical parts often encountered in production. It should be noted that because the original authors of the examples were limited by the environment and conditions at the time, the repair methods and welding materials used were not necessarily the most advanced and reasonable, but I still hope that the readers can learn from these examples . This book focuses on the concise explanation and practical application of technical points. Through analysis of some welding repair examples, it can help readers improve welding repair skills, understand and learn methods and some special skills to solve general welding repair problems. This book is widely applicable. It is mainly used by engineering and technical personnel, managers and operators who are engaged in materials, machinery manufacturing and welding technology, especially those who are responsible for on-site construction, and middle and senior technical workers. The relevant teaching and scientific research personnel of universities, research institutes, enterprises and institutions are referenced.

This book explains the welding repair technology of damaged parts in engineering structures from the perspective of practicality. It is concise and practical, and has the significance of guiding practice. This book highlights the technical characteristics and applications of welding repair, which can help readers understand and learn methods and some special techniques for solving general welding repair problems. Some new processes and successful experiences have been added, and a large number of application examples of welding repair of various mechanical parts often encountered in production have been interspersed. The readers can learn from these examples. ^[1]

Edition: First edition

Sheets: Paperback

Chapter 1 Overview

1.1 Characteristics of welding repair 1

1.1.1 Repairing broken or worn parts 1

1.1.2 Repair-manufacturing new parts: remanufacturing technology 2

1.2 Wear and corrosion of metal surfaces 3

1.2.1 Metal wear and influencing factors 3

1.2.2 Corrosion of metal surfaces and influencing factors 10

1.3 Application Status and Prospects of Welding Repair 13

1.3.1 Application Status of Welding Repair 13

1.3.2 Application Prospects of Welding Repair 15

Chapter II Welding Repair Methods and Materials Used

2.1 Common welding repair methods 18

2.1.1 Arc Welding Repair 18

2.1.2 Metal Surface Spray Repair 23

2.2 Applicability of welding repair methods 27

2.2.1 Selection of welding repair methods 27

2.2.2 Comparison of various welding repair methods 30

2.3 Materials used for welding repairs 32

2.3.1 The characteristics of common repair electrodes 32

2.3.2 Model and Grade of Welding Electrode 33

2.3.3 Characteristics of repair wire and flux 55

2.4 Types and Characteristics of Surfacing Alloys 59

2.4.1 Types of Surfacing Alloys 59

2.4.2 Application Features of Surfacing Alloys 65

2.4.3 Selection of Surfacing Alloys 67

Chapter III Repair Technology of Electrode Arc Welding

3.1 The characteristics and process of electrode arc welding 69

3.1.1 Characteristics and application scope of electrode arc welding 69

3.1.2 Electrode arc repair equipment and auxiliary tools

3.1.3 Key points of electrode arc welding repair process 73

3.2 Application Examples of Electrode Arc Welding Repair 77

3.2.1 Arc Welding Repair of Electrode for Shaft Parts 77

3.2.2 Welding repair of damaged parts of power station equipment

3.2.3 Welding Repair of Auto Parts 93

3.2.4 Welding repair of damaged parts of rolls and large-scale coil rolling machines

3.2.5 Repair of cracks on the inlet end cover of coal mill and water tank of expander 100

3.2.6 Repair of Cracks in the Bottom of Gas Generator 103

3.2.7 Repair of ZG42CrMo track beam and lifting column 105

3.2.8 Welding and repairing of dissimilar steel and stainless steel composite plate of urea absorption tower 107

Chapter 4 Gas Welding Repair Technology

4.1 Features and Technology of Gas Welding Repair 110

4.1.1 Features of Gas Welding Repair

4.1.2 Device for gas welding repair 111

4.1.3 Gas welding repair process 114

4.2 Examples of gas welding repair

4.2.1 Gas Welding Repair of Rails 123

4.2.2 Gas welding of gearbox and gear 125

4.2.3 Gas Welding Repair of Cast Iron Cylinder Head and Main Bearing Holes of Cylinder Block 127

4.2.4 Gas Welding Repair of Plain Bearings and Bushes 129

4.2.5 Gas Welding Repair of Aluminum Cylinder Heads and Electrode Plates

Chapter V Submerged Arc Surfacing Welding Technology

5.1 Classification and Characteristics of Submerged Arc Surfacing Welding 134

5.1.1 Classification of Submerged Arc Surfacing Welding 134

5.1.2 Features of Submerged Arc Surfacing Repair 136

5.2 Submerged arc surfacing process and parameters 137

5.2.1 Main process parameters 137

5.2.2 Factors Affecting the Quality of Submerged Arc Surfacing Welding 140

5.3 Application examples of submerged arc surfacing repair 143

5.3.1 Submerged arc surfacing repair of alloy structural steel 143

5.3.2 Submerged arc surfacing repair of steel rolls 153

5.3.3 Submerged arc surfacing of valve sealing surfaces

5.3.4 Submerged arc surfacing repair of flux-cored wires 167

5.3.5 Submerged arc surfacing repair of forged hammer base 171

Chapter 6 Gas Shielded Welding Repair Technology

6.1 Technical characteristics of gas shielded welding repair 173

6.1.1 Tungsten arc welding repair technology 173

6.1.2 Fused-electrode gas shielded welding repair technology 174

6.1.3 Self-protected tubular welding wire surfacing repair 177

6.2 Tungsten Arc Welding Repair Example 179

6.2.1 Surfacing of Aluminum Bronze Valve Seal Surfaces

6.2.2 TIG welding repair of dissimilar steel steam pipes 180

6.2.3 TIG Welding Repair of Large Soft Face Gear Tooth 181

6.2.4 Soldering and Repairing of Tin Bronze Bells

6.2.5 TIG welding repair of marine propellers 184

6.2.6 Tungsten arc welding repair of steam turbine rotor 185

6.2.7 Tungsten Arc Welding Repair of Torque Converter 188

6.3 Example of Gas Shielded Welding Repair of Melting Electrode 188

6.3.1 MIG Welding Repair of Aluminum Tanker 188

6.3.2 CO2 Welding Repair of Large Ball Mill Crack 190

6.3.33 Ar + CO2 Welding Repair of Cracks in T Forged Hammer Base 192

6.3.442CrMo sprocket argon-rich gas shielded welding 192

6.3.5 CO2 Gas Shielded Welding Repair of Cast Steel 194

6.3.6 CO2 welding repair of diesel engine block, cylinder water jacket and air compressor block 194

6.3.7 Welding repair of cracks in rotor bracket of hydro-generator

6.3.8 Welding Repair of the Root Wear of the Drum of the Drawing Machine 200

6.3.9 Repair of cracks in the liner of the power plant turbine room 202

Chapter VII Plasma Arc Surfacing Welding Technology

7.1 Characteristics and Process of Plasma Arc Surfacing 205

7.1.1 Process characteristics of plasma arc surfacing 205

7.1.2 Plasma arc surfacing methods and materials 207

7.1.3 Plasma arc surfacing equipment, accessories and process parameters 210

7.1.4 Application Range of Plasma Arc Surfacing Repair 214

7.2 Application of Plasma Arc Surfacing Repair 215

7.2.1 Plasma arc surfacing of cobalt-based alloy powder 215

7.2.2 Plasma arc surfacing of nickel-based alloy powder 217

7.2.3 Plasma arc surfacing of iron-based alloy powder 217

7.2.4 Wire Plasma Plasma Arc Surfacing Process 218

7.3 Examples of plasma arc welding repair applications 221

7.3.1 Mold Plasma Arc Surfacing Repair 221

7.3.2 Plasma arc welding repair of compressor crankshaft 222

7.3.3 Plasma Arc Welding of Exhaust Valves 224

7.3.4 Powder Plasma Arc Surfacing Repair of Agricultural Machinery Parts 226

7.3.5 Plasma Arc Welding Repair of Oral Cobalt Chromium Alloy 228

7.3.6 330MW Steam Turbine Low Pressure Rotor Blade Fracture Repair 229

Chapter VIII Spray Repair Technology

8.1 Spray Repair Features and Materials 232

8.1.1 Features of Spray Repair

8.1.2 Equipment used for spray repair 233

8.1.3 Spray repair materials and selection 236

8.2 Process Points for Spray Repair 245

8.2.1 Preparations before spray repair

8.2.2 Selection of spray repair process parameters 247

8.3 Spray Repair Application Examples 251

8.3.1 Spray repair of engine crankshafts

8.3.2 Spray repair of hydraulic machine plunger surface 255

8.3.3 Supersonic arc spraying of water-cooled walls of utility boilers 256

8.3.4 Plasma arc spraying of engine blades 257

8.3.5 Spray repair of casing high pressure water cooler 258

8.3.6 Spray repair of copper blast furnace tuyere 258

8.3.7 Spray repair of high-pressure flat valve gates and rails 259

8.3.8 Spray Repair of Water Tank Drawing Machine Parts 261

Chapter IX Quality Inspection of Welding Repair

9.1 Common Defects and Preventive Measures 263

9.1.1 External Defects and Their Prevention

9.1.2 Internal Defects and Their Prevention

9.2 Quality inspection methods for welding repair 271

9.2.1 Visual inspection of the repair layer

9.2.2 Inner Quality Inspection of the Repair Layer

9.2.3 Inspection of Surface Hardness and Abrasion Resistance 279

9.2.4 Inspection of the compactness and pressure resistance of the repair layer 281

9.3 Example of quality inspection of welded repair parts 283

9.3.1 Quality inspection of repair welds for medium pressure gas storage tanks 283

9.3.2 Inspection of welding quality of stainless composite steel dewatering tanks 284

9.3.3 Inspection after Welding Repair of Synthetic Ammonia Tower Heat Exchanger 285

references