Aplicación ARM

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material
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Application of Abrasion-Resistant Material
Nmero de medio -SEBF8782-00 Fecha de publicacin -03/09/2002 Fecha de actualizacin -04/09/2002 SEBF87820001
Application of Abrasion-Resistant Material

SMCS - 0679; 0751
SEBF8782 August 2002 SMCS Codes: 0679, 0751
GUIDELINE FOR PRODUCT UPDATE Application of Abrasion-Resistant Material

All Machines That Are Equipped with Ground Engaging Tools (GET)
Table of Contents
Introduction 2
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 01/12/2010
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Necessary Equipment 3 Safety Equipment 6 Equipment Sources 6 Basic ARM Welding Process 8 Spray vs. Globular Transfer 9 Transition Current 9 Basic Weld Parameters for ARM 9 Getting Ready 10 Welding Parameters Sheet 11 Getting Started 12 Evaluating Quality of ARM Beads 13 Specifics for Caterpillar Parts 14 Miscellaneous Information 16 Production Costs 16 Cost Calculation Tables 17-18
Introduction
Caterpillar has developed a weld operation to apply carbide particles to the wear surface of Caterpillar Ground Engaging Tools (GET), and to other parts where the process would be beneficial. Although the weld bead is made with general filler wire, the carbide particles are held in place to resist tool wear. The application, known as Abrasion Resistant Material (ARM), is intended for high abrasion and low to medium impact loads. When working in fine, loose material, the operation typically increases the life of GET components by a factor of five or more times. High impact loads, such as large rocks or chunks of concrete, may cause the beads to break off the surface of the piece. This guideline provides a list of required equipment, and outlines the procedure recommended by Caterpillar. Also included are miscellaneous process tips gathered from experience. If the Caterpillar procedure is learned and followed, dealer stores can receive a letter of certification from Dealer Support that ensures company warranty coverage of tips to which ARM is applied. Dealer Support personnel are available to provide training/certification instruction on-site if desired. The choice of equipment will affect the investment required to set up the operation.
Illustration 1 A.R.M. Equipment
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Personal injury or death can result from electric shock, from the fumes, gases, and ultraviolet rays of the weld arc, and from other work necessary in the ARM process. Protect yourself and others; read and understand this warning. Welding fumes and gasses can be dangerous to your health. Use ventilation, exhaust at the arc, or both, to keep fumes and gasses from your breathing zone and the general area. Ultraviolet rays from the weld arc can cause blindness and burn skin, and prolonged exposure can lead to skin cancer. Due to the high current, these effects are more severe with an ARM process than with other welding operations. Wear correct eye, head, and body protection during welding. The wearing of safety glasses, preferably with side shields, must be mandatory for all people at all times in your shop area. Electric shock can kill. Do not touch live electrical components. Make sure safety caps are always in place on all gas cylinders unless they have been secured in a fixture for use. Read and understand the welding equipment manufacturers instructions, and your employers safety practices. See American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Dept. of Labor.
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U.S. Dept. of Labor Washington, D.C. 20210
Necessary Equipment
One option in setting up an ARM operation is to use existing equipment. A second option is a machine developed by Caterpillar and supplier Rodger Spriggs. The following bulleted points provide guidelines as to what is necessary, and include some explanations. Sources of equipment are listed under the "Equipment Sources" heading.
Although the function may seem somewhat similar, equipment for submerged arc operations will not work for ARM. Instead of a flux delivery hopper, a carbide particle feed system is necessary to deliver the particles to the weld bead at a controlled rate. One example is the vibratory feeder unit available from Rodger Spriggs (see Illustration 2). The major components consist of a vibratory feeder assembly, control box, particle hopper, metering pipe, and adjustable feed tube assembly.
Illustration 2 Vibratory Particle Feeder
ARM requires a mechanism for precision control of weld torch travel. The travel of the carriage that carries the torch must be smooth and consistent, and the speed must be adjustable. Surplus track rebuilding machines can be adapted for this purpose. Dealer Support has received inquiries about the feasibility of using robots for ARM torch control. Although it is possible to do so, a motion/function control "do loop" would have to be developed and recorded for each part number to be run. Also, a precision table-mounted fixture system would be necessary to hold each individual part in exactly the same spot, so the ARM beads would be applied to each part consistently. Because of this, robots are better suited for production welding, as opposed to individual piecepart work. Although individual stringer (straight) beads can be applied and overlapped without it, a weld head oscillator is strongly recommended for use with the carriage. The adjustable side-to-side speed and width movement, along with adjustable torch delay
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at each side, allow precise process control when applying wide ARM beads. Also, less time is required to apply wide beads to parts and less heat is transferred to the base metal. Beads of 1 to 1.38 in. (1.5 in. maximum) can be easily run. A control unit, power supply, and connection cables capable of 600 DC Amperes are required. Correct ARM application requires extremely high current levels. Power supply examples are a DC-600 by Lincoln, and Deltaweld 652 by Miller. A water-cooled torch system must be used. The high ARM current and heat will destroy a torch without this feature. Examples of water cooled torches are the Binzel RB 610 D, Lincoln Magnum 450WC, and Tweco TAM500-332.
Illustration 3 Water Cooled Torch and Particle Feed Tube
A CO/Argon regulator, gas hose, and solenoid-controlled valve are necessary to provide shielding gas. The hose must be long enough to accommodate the full range of carriage movement from wherever the gas cylinder is secured. 98% Argon/2% Oxygen shielding gas is recommended. Most welding operations use a 75% Argon/25% CO2 mixture, but to produce good penetration and large weld pool, a higher Argon concentration is required. 90% Argon/10% CO2 can be used, but the oxygen in the preferred mixture helps to blend the edge of a bead with the base metal. Shielding gas usage will be approximately 1000-1100 l/hr (35-40 ft/hr). AWS class ER70S3 weld wire such as Lincoln SuperArc L-50 should be used in the operation. It is a solid, general application wire, and works best for creating the large weld pool. Wire sizes from 0.76 mm (.030 in.) to 2.4 mm (.094 in.) have been used, but 1.5 mm (.062 in.) is a good choice for general ARM work. A wire reel assembly and drive rolls capable of handling the above wire is also necessary. Any existing wire straighteners and swivel mounting plates can probably be reused. A welding table with a surface made of 19 to 25 mm (0.75 or 1 inch) steel plate is required to provide a surface for welding, clamping, and preheating operations. It should be about 3 to 4.5 m (10 to 15 ft.) long and 1 m (about 3 ft.) wide, and adequately reinforced. Holes for studs or bolts should be added to the table surface to clamp and pre-bend long parts, where weld distortion can be a problem. The table can be separate, or part of the torch carriage system.
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Illustration 4 Table for Welding Equipment
An abrasive chop saw of sufficient capacity is needed to section samples for inspection. Examples are DeWalt DW871 or Milwaukee 6176-20. Carbide particles of ASTM (American Society For Testing And Materials) size 12 to 35 are recommended by and available from Caterpillar. Screen mesh sieves of ASTM 12, 20, and 35 are the best way to clean excess carbide particles before they are reused (see Illustration 5).
Illustration 5 Screen Mesh Sieves
A central control panel is needed, to control: Power supply Wire voltage (current) and speed Carriage speed Particle feed rate Torch cooling Oscillation functions and delays Shielding gas flow
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Illustration 6 Control Panel for A.R.M. Equipment
The control panel should incorporate automatic start for the shield gas, adjustable delay times for carriage travel and feeder when the weld arc is started, and delay for feeder stop when the bead is stopped. Another recommended feature is an electrical interlock that prevents the wire from being energized if the torch cooling water is not flowing. All adjustable parameters should be controlled by pointed knobs on 270 potentiometers. These should be mounted with graduated (for example 0-10.0) face plates. There is no need for face plate graduations to correspond to actual values of functions such as carriage speed or delay times. The purpose is so that a perfected set of adjustments can be recorded, and exactly duplicated, the next time the same parts are run. In addition to equipment listed above, there are other essential or highly recommended items: An angle grinder is an indispensable tool for an ARM set up. Use it to remove rust, dirt, grease, and paint from parts, to ensure good conductivity and prevent bead contamination. Insulation blankets are a convenient method of providing slow cooling for completed parts such as DH-3 tips, to prevent cracking due to residual stress. For the same reason, a natural gas or acetylene torch and an infrared thermometer are used to preheat certain parts such as long scraper blades. An assortment of spare parts such as torch tips should be kept on hand to prevent downtime. The Rodger Spriggs machine is shown in Illustrations 1 and 4. This machine meets all Caterpillar specifications and can be specified for local power systems anywhere in the world. It is nearly a turnkey ARM set up, since everything listed under "Necessary Equipment" is included except for the welding table, gas regulator, consumables, and inspection equipment. See the "Equipment Sources" heading for Spriggs contact information.
Safety Equipment
Along with process equipment, there are a number of extremely important pieces of equipment that are required or strongly recommended for safety purposes:
Because of the high current levels and Argon shielding gas used in ARM operations, a welding helmet lens of shade 13 or 14 should be used. Shades 9 to 11 are usually
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used for general arc welding operations. Some helmet manufacturers offer thin shade inserts which increase lower shaded helmets to 13 or 14.

The wearing of safety glasses, preferably with side shields, must be absolutely mandatory for all personnel at all times in the ARM area, as well as anywhere in your shop. A face mask provides added eye protection when using hand-held grinding equipment. The high ultraviolet radiation also requires all skin to be covered by fire-resistant protective clothing. Heavy insulating gloves, such as those made of leather, should be worn by operators. Because of the increased danger from electric shock, care should be taken not to get them wet if samples are being water cooled for inspection. Moisture from heavy perspiration also increases shock danger. Another item is a weld fume extraction system. A flexible hose can be affixed to the carriage and connected to a wall-mounted system, to remove hazardous fumes and smoke. Floor fans can be used to help with ventilation, but be sure the shielding gas function is not affected. During initial setup of the equipment, it is necessary to install a fixture to secure the shielding gas cylinder. It should be firmly mounted on a wall or building support beam, with sufficient space for changing out cylinders safely.
Equipment Sources
The Caterpillar Service Technology Group (CSTG) offers a variety of welding-related equipment including helmets, hand grinders, personal protective jackets, and hand tools. Caterpillar recommended carbide particles are offered in a 22.7 kg (50 lb.) bucket, part number 9W-3679. Consult the Tool and Shop Products Guide (NENG2500, includes CD) or call (800) 542-8665 in the US, or +41 (22) 849 40 36 in Geneva for tool information and part numbers. In addition to a complete ARM machine, individual components such as vibratory particle feeders are available from Rodger Spriggs. The address is: Rodger W. Spriggs 2005 West Raymer Ave. Unit "O" Fullerton CA 92633 (714) 879-5875 Fax: (714) 879-3159 Email: rwspriggs@hotmail.com Along with basic welding equipment, Lincoln Electric can supply nearly all the miscellaneous items necessary for an ARM system, including torch cooling systems, weld fume extraction systems, particle feeders, and weld head oscillators (Lincoln Spreadarc). They also have sales and support outlets all over the world.
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The Lincoln Electric Company 22801 St. Clair Ave. Cleveland, OH 44117 (216) 481.8100 Fax: (216) 486.1751 Website: http://www.lincolnelectric.com A carbide particle feeder, model FT-0C, is available from: FMC Syntron 57 Cooper Ave. Homer City PA 15748-9234 (800) 362-8999 Fax: (724) 479-4552 Website: http://www.fmcsyntron.com Another supplier with an extensive line of welding equipment is: Miller Electric Manufacturing Co. 1635 W. Spencer St. P.O. Box 1079 Appleton, WI 54912-1079 (920) 734-9821 Fax: (800) 637http://www.MillerWelds.com
Abicor Binzel can supply water cooled torch systems and cooler interlock switches: Alexander Binzel Corporation 650 Research Drive, Suite 110 Frederick MD 21703-8619 (800) 542 4867 Website: http://www.binzel-abicor.com
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Personal protective clothing, protective screens, and insulating blankets are available from: Steiner Industries 5801 North Tripp Ave. Chicago IL 60646-6013 (800) 621-4515 Fax: (773) 588-3450 Website: http://www.steinerindustries.com email: info@steinerindustries.com A source of multi-layer silica type insulating blankets is: Superheat Services, Inc. 8450 W. 191st Street # 14 Mokena IL 60448 (815) 464-2675 Fax: (815) 464-2681 Air quality maintenance equipment suitable for grinding dust as well as welding fumes, is available from: Air Quality Engineering 7140 Northland Drive North Brooklyn Park MN 55428-1520 (800) 328-0787 Fax: (763) 531-9900 Website: http://www.air-quality-eng.com
Sources of welding helmets are: Hornell, Inc. 2374 Edison Blvd.
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Twinsburg OH 44087 (800) 628-9218 Fax: (330) 425-4576 Website: http://www.hornell.com Sellstrom Manufacturing Co. One Sellstrom Drive Palatine IL 60067 (800) 323-7402 Fax: (847) 358-8564 Website: http://www.sellstrom.com Jackson Products 5801 Safety Drive N.E. Belmont MI 49306 (800) 253-7281 Fax: (616) 784-7870 Website: http://www.jacksonproducts.com ASTM screen mesh sieves are available from these two sources: Fisher Scientific UK Ltd Bishop Meadow Road, Loughborough, Leicestershire LE11 5RG 01509 231166 Fax: 01509 231893 email: info@fisher.co.uk Website: http://www.fisher.co.uk W.S. Tyler 8570 Tyler Boulevard
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Mentor, Ohio, USA 800-321-6188 Fax: 440-974-0921 Email: wstyler@wstyler.com Website: http://www.wstyler.com Welding related shop equipment including abrasive wheels is available from Forney Industries: Forney Industries, Inc. Central Office P.O. Box 563 1830 LaPorte Ave. Ft. Collins, CO 80521 (800) 521-6038 Fax: (970) 498-9505 Website: http://www.forneyind.com/ Weld head oscillators are also available from: Gullco International Inc. 21568 Alexander Road Cleveland, Ohio, 44146 (440) 439-8333 Fax: (440) 439-3634 Website: http://www.gulco.com The sources listed in "Equipment Sources" are not intended as the only choices. Useful information on welding operations, as well as numerous equipment manufacturers, can be found in welding industry publications such as Welding Design and Fabrication. Your local welding equipment supplier can assist in equipment selection, and will have many components available to get your operation restarted in case of equipment failure. You can also contact Dealer Support at (309) 675-8263 if you have questions about any equipment.
Basic ARM Welding Process
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Simply stated, the ARM process is done by precision control of a Gas Metal Arc Welding (GMAW) weld torch, with a carbide particle feed system. The torch creates a pool of molten base metal and weld wire, called the Drop Zone Area (DZA). The particles are fed into the DZA by a feed tube that is mounted behind the torch. The particles become suspended in the pool as the torch continues moving and the pool hardens. Table 1 lists a number of variables and their effect on the size of the DZA.
Table 1
Effect of Weld Variables on DZA Size Increase in: Amperage Voltage Stickout Distance Travel Speeds Wire Size Particles Oscillation Width DZA: Increases Increases Little Change Decreases Increases Decreases Increases
Spray vs. Globular Transfer

The ARM arc differs from ordinary GMAW operations in that it is done with current levels high enough to produce a "spray" wire metal transfer instead of the usual "globular" transfer (see Illustration 7). At low welding currents, liquid metal is transferred from the wire to the workpiece in large globular drops. Globular transfer produces an uneven sound, similar to frying eggs. When viewing a globular arc, the end of the wire is rounded and there is a considerable amount of weld spatter. Above a critical current level, the liquid steel transfer becomes a smooth, cone shaped spray of very small droplets. The spray arc is very stable, and the end of the wire tapers down to a point. This arc is characterized by an even sound, similar to a soft buzz, and there is very little or no weld spatter. Because spray transfer current levels are high, there is much more ultraviolet radiation.
Illustration 7
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Sketches of spray and globular transfer
Transition Current
The current level at which the arc takes the spray form is known as the transition current. Transition current is not a fixed level, because it is dependent on a number of parameters. The most important of these is the voltage adjustment, but size and speed of the wire, and the type of shielding gas also have an effect. Table 2 gives examples of wire diameters and speeds, and the start of transition current levels, using the 98% Argon/2% Oxygen shielding gas. Although current levels during actual ARM operation will be higher than those listed in Table 2, the object is only to ensure adequate penetration and create an acceptable DZA to capture particles, not to maximize current. Too much current causes extreme heat buildup in the part, which should be avoided.
Table 2
Sample Transition Current Adjustments Current Wire Diameter 1.14 mm (0.045 inch) 1.57 mm (0.062 inch) 1.98 mm (0.078 inch) 2.39 mm (0.094 inch) (Amps) 220 275 310 370 Wire Speed/min. 6375 mm (251 inch) 4546 mm (179 inch) 3454 mm (136 inch) 3124 mm (123 inch)
Basic Weld Parameters for ARM

There are a number of important parameters for good ARM application:

Sufficient voltage (current) Wire size and speed rate Carriage travel speed Oscillation speed, width, and delays Distance "A" (distance of particle feed tube to torch tip) Visible stickout (distance of torch to workpiece) Particle feed rate
There is no single "correct setting" for each adjustment. The parameters interact with each other, and acceptable beads can be run with different but offsetting adjustments.
Getting Ready
When connecting the power supply, make sure the system is set up for reverse polarity (wire is positive [+]), to ensure good penetration. Because of the high current flow, the table should be grounded to the power supply from two opposite corners. This also prevents the tendency of the arc to aim in the direction of a single ground connection. Check all
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mechanical functions, especially the wire feeder, carriage travel, particle feeder, and oscillator, to be certain that everything is operating consistently.
Serious injury or death can result if the valve breaks off a falling gas cylinder. Never connect, or remove the safety cap from the shielding gas cylinder or any other type of cylinder, unless it has been secured in its holding fixture. Shop personnel must be required to keep valve safety caps in place on all unused cylinders. All test samples or parts to receive ARM should be free of oil or grease and completely dry. Use an angle grinder to remove dirt, paint, and loose or excess scale and rust from the weld surface. This can also be done by sand blasting. The surface does not have to be perfect, but cleaning ensures good electrical contact and helps prevent contamination and porosity in the ARM bead. A light surface grind to clean the table contact points of the part is also recommended, to ensure adequate current flow from the part to the table. The particle feed tube should be a 13 mm (.5 inch) diameter tube, modified and installed aiming toward the torch as shown in Illustration 8. Copper tubing can be used to make the tube, but stainless steel tubing will last longer. Use a vise or hammer to form the oval shape in the end of the tube. This helps to distribute the particles across wide beads. On many installations, the top of this tube has a funnel to catch the particles from the stationary feeder as the tube oscillates with the torch (see bottom of Illustration 2). Do not allow the torch-mounted funnel/tube to touch the feeder distribution tube. Distance "A" (between the tube and the torch) must be adjustable. Because of the adjustment feature, the tube can easily be bumped out of alignment when placing parts on the table. Be sure to check the tube often during operation, to make sure it is centered with the line of torch travel. Distance "A" measurements can be taken from the outer housing of the torch to the center or edge of the feed tube, or along the adjustment mechanism that holds the tube. The actual measurement method is not important, as long as the measurements are accurate and consistent, and can be recorded for duplication later. The vertical length between the torch tip and the workpiece is known as visible stickout (see Illustration 8). Stickout is usually set around 16 mm (0.63 inch) to 22 mm (0.88 inch). If tips with an uneven surface height are to be run, either support the part with steel shim blocks or make a fixture to fit the part, so that the line of the average weld surface is as level as possible. Set the stickout dimension to the average weld surface of the part.
Serious injury or death can result from contact with an energized weld wire. Do not use a metal ruler to check visible stickout. Make and use marked wooden gage blocks of the most-used stickout dimensions.
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Illustration 8 (1) Detail for the end of the feed tube (2) Length of stickout (3) Base metal
Welding Parameters Number____________
Illustration 9 (2) Length of stickout (3) Base metal (4) Weld pool (5) Feed tube Table 3
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Wire Diameter
Traverse Speed
Type of Welding Wire
Wire Feed Rate
Width of Weld Bead
Voltage
Height of Weld Bead
Amperage
Weld Penetration
Setting of Carbide Feed Machine Carbide Feed Rate
Shielding Gas
Flow Rate
Width of Oscillation
Visible Stickout
Speed of Oscillation
Dimension (A)
Dwell of Oscillation (Right and Left)
Notes:
Getting Started
SAE 1018, or any soft steel bar stock of 1 X 2 X 6 inch or similar dimensions is ideal for running sample beads. Torch oscillation should begin immediately when starting the arc, but carriage travel and particle feeding should be slightly delayed. This is necessary to establish an adequate weld pool to receive the particles. The oscillation rate is usually slightly more than one shift per second, and oscillation widths of 16-19 mm (.63-.75 in.) are usually used. Feeder operation should continue for a brief time after the arc is stopped, to be sure the end of the bead is filled with particles. The key to the operation itself is practice. In this way, the effect of changing parameters can be learned by inspecting beads. When making various adjustments, be sure to adjust only one parameter at a time prior to each test, to get a feel for the result of changing individual variables. Use a paint stick to mark samples with progressive numbers. Record the sample number and all parameter settings on copies of the Welding Parameters sheet. Samples and their respective settings can then be easily compared. To begin, run beads with different adjustments including oscillation parameters, but without adding particles. When the plain beads are acceptable, record and save these settings on a copy of the Welding Parameter sheet. The settings can be duplicated when it is necessary to run butter beads. The function of butter beads is discussed in the "Applying ARM to Caterpillar Parts" heading. After practice with plain beads, experimentation with particle feeding can begin. Adding room-temperature particles cools the DZA pool. To compensate, torch speed should be decreased by about 25%. Adjustments to voltage (current), and wire speed will also likely be required.
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Although the potentiometer setting numbers for adjustments such as carriage, wire, and oscillation speeds will not correspond to their actual values, a stopwatch can be used to obtain these numbers. Wire feed rate can be calculated by running an un-energized wire for exactly 15 or 30 seconds and measuring the length. The values can be compared to examples provided in Table 3, and will also be used in calculating the cost of ARM for parts. See Illustration 10 for a diagram of oscillating torch travel and ARM bead cross-section. The alternating lengthwise penetration is the result of torch dwell at each side. Dwell of the torch at the sides of the ARM bead is important to establish and maintain beads of the desired width. When welding along the center of symmetric parts or parts with extensive cross-section area, dwell should be even on both sides. To run beads lengthwise along the edge of a part, for example a scraper blade, a shorter dwell along the edge is desirable since there is less area for heat sink.
Illustration 10
After running ARM samples, cool them and use an abrasive wheel chop saw of sufficient size to make a clean, smooth cut through the bead for inspection of penetration and particle dispersion. Since the particles are very hard, softer abrasive wheels are generally more successful to prevent wheel loading and minimize burning. Bead inspection is covered on pages 12 and 13. Later on, as parameters for given parts are optimized, keep a binder of parameter sheets marked with the part number of each part. With these sheets, set up time is significantly reduced each time the same parts are to be run. Good quality test samples, or sectioned tips with the ARM surface repainted, can be put on display to encourage ARM sales. Table 3 lists sample parameters of ARM beads. These are intended as starting points or examples, and most likely would not be duplicated exactly.
Table 4
Parameter
Wire Size Voltage 26
Sample Setup Parameters Initial Settings

1.14 mm (.045 inch) 1.57 mm (.062 inch) 30 1.98 mm (.078 inch) 32 2.39 mm (.094 inch) 34
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Amperage Travel Speed Wire Feed Speed Shielding Gas Visible Stickout Bulk Feed Rate (1) Distance "A"
280 146 mm/min (5.75 in/min) 889 cm/min (350 in/min)
320 152 mm/min (6 in/min) 457 cm/min (180 in/min)
98% Argon and 2% Oxygen at 1.1 CM/H (40 CF/H) 12.7 mm (.50 inch) 19.0 mm (.75 inch) 22.2 mm (.87 inch) 25.4 mm (1.00 inch)
0.23 kg/min (.5 lbs/min) to 1.23 kg/min (2.7 lbs/min) 15.9 mm (.63 inch) 19.0 mm (.75 inch) 22.2 mm (.87 inch) 25.4 mm (1.00 inch)
(1)
Hard particle feed rates will vary greatly, based on the differences in particle feed systems
NOTICE Although water can be used to cool test samples for inspection, GET tips or other parts intended for sale and/or use should never be water cooled. Rapid cooling can cause stress cracks in the base metal. Also, ARM should not be applied to parts immediately after they are brought into the shop from outside storage in cold climates. Allow them to reach ambient room temperature, or preheat as necessary. Particles that fall to the side of the beads should be gathered and reused, but it is important to prevent bead contamination by removing dirt and other foreign material. First, sweep a magnet about 13 mm (0.5 inch) above the particles as they lay on the table. This will attract high iron debris such as weld berries and pieces of wire. Next, stack 12, 20, and 35 mesh screens with the 12 on top, over a bucket. Gather the particles and shake them in the screens. This holds any large debris on top and lets fines fall into the bucket, so the cleaned particles can be returned to the hopper. The 20 screen stops half of the particles so they do not clog the 35 screen.
Evaluating Quality of ARM Beads

There are four main goals in producing good quality ARM beads:

Proper density and optimized distribution of particles Proper penetration Smooth blend to the base metal at bead edges No cracks in the base metal
Penetration depth is much easier to see if the cut surface has been etched. A mixture of 9095% methanol alcohol and 5-10% nitric acid should be prepared and applied to the section surface with a cotton swab or small squeeze bottle. Rinse the part in water to remove excess acid after etching. Be careful to avoid skin contact when using this mixture.
Visually, the area of an ideal ARM bead cross section should be comprised of a 50% wire and base metal mixture, and 50% particles (see Illustration 11). The particles should be as evenly distributed from side-to-side and top-to-bottom as possible. Perfect distribution is
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difficult to achieve because some of the particles will melt into the hotter top of the pool, and many tend to sink to the bottom. Optimizing distance "A" is a good method of getting the best distribution. At minimum, the bottom 75% of the weld bead should have good particle distribution and only the top quarter may have a reduced amount of particles. By weight, a bead should be 40% wire and 60% particles. These numbers are checked by a series of weight measurements. Contact Dealer Support at (309) 675-8263 for weight inspection procedure details. When running oscillating beads, the particle deposit should be one pound per 32-36 inches of bead length. Bead height will usually be about 4-5 mm (0.16-0.20 inch). Penetration should be approximately 1.5 to 2.0 mm (0.06 to 0.08 inch) at the center of oscillating beads. Proper penetration is achieved mainly by adjusting carriage and oscillation travel speeds, and the current level.
Illustration 11
Stringer (straight) beads tend toward a penetration of about 5 mm (0.20 inch) at their center, because the heat is concentrated in a straight line. Stringer bead penetration should be checked toward the edge of the bead. Stringer beads can be run side-by-side to achieve the wide coverage of oscillating beads, but this procedure takes extra time and much more heat is transferred to the part.
Cracks may occur in the ARM bead due to the stress of uneven heat buildup from welding. This is especially true when applying long beads to thinner parts. Cracks in the ARM bead itself are acceptable, but if they are seen in the base metal, the part should not be used. These cracks will likely grow and result in failure of the piece.
Illustration 12
It is also important to make sure the blend of ARM beads to the base metal is fairly smooth (see Illustration 12). Beads should not be "piled up", appearing as a puddle of liquid mercury on a surface. A smooth blend helps prevent any large pieces of material being handled by the machine, from catching on the edge of the bead and breaking it away from the base metal. Likely causes of high bead edges are too much carriage speed and/or insufficient current level (even if in spray transfer).
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Specifics for Caterpillar Parts

Tips of DH-3 material are prone to stress cracking when applying ARM, therefore, preheating and slow cooling are recommended for these parts as well as any high carbon parts. The Caterpillar-recommended preheat procedure is to run a "butter bead" on the intended ARM surface. Butter beads are simply beads using the same wire, but with no carbide particles. While the butter bead is still warm, apply an ARM bead on top of it. Butter beads have the added advantage of diluting the base metal with weld wire, and providing a crack-arresting layer between the base metal and ARM bead.
Although not the best procedure for DH-3 and high carbon parts, it is also possible to preheat with a gas torch. If using this method, do not allow the flame to touch the surface area where the ARM bead will be applied. The preferred procedure is to heat the tip from the opposite side. Heat the tips to 200 to 260C (400 to 500F) and use an infrared thermometer to monitor the temperature. Regardless of which preheat method is used, cover the part(s) with an insulating blanket after applying the ARM bead to slow the cooling rate. Cooling can also be slowed by putting the tips in a container as they are finished, and covering them with dry sand. Torch preheating, and also applying beads to long parts in sections as opposed to one continuous bead, helps control warping of long parts such as scraper blades. Prebending the part to a slightly concave shape (in relation to the torch) can also prevent warping. This can be done with blocks and clamps on the table surface. After running the bead(s), allow the piece to partially cool before releasing the clamps. Through testing, a procedure can be perfected and recorded for your particular ARM installation. When applying ARM to tips, start the bead at the end of the tip and move toward the retaining housing. Running the bead toward the tip end causes an extreme heat buildup at the point, because there is not as much metal to act as a heat sink. Through service tests, Caterpillar Inc. has developed a series of standard ARM bead patterns for various tips. These patterns provide the best balance of service life extension versus cost of application, and are used to apply ARM to the tips available from Caterpillar. Contact Dealer Support if you would like to obtain dimensions of these patterns.
Some machines have high wear areas, for example areas inside scraper bowls, which can benefit from ARM patterns. Since these large areas cannot be done on a table, it is possible to overhead-mount a particle feeder with a long flexible feeder hose, and fasten the delivery tube to an ordinary hand held torch. Although it is impossible to produce the quality of ARM described in this publication, it will still add a degree of abrasion resistance to surfaces. Caterpillar GET tips with, and without ARM, undergo a heat treat operation. This provides an extra measure of hardness to the base metal, for wear resistance. Tips with ARM are heat treated after the ARM beads are applied. When ARM is applied to Caterpillar tips in dealer shops, the heat draws some of this hardness out of the part. This is the reason why excessive heat should be avoided. Although the Caterpillar heat treatment does provide some additional life, in most cases it is not required for tip service. The wear resistance of a good quality ARM bead will significantly increase the life of any GET part to which it is
Page 22 of 25
applied. The exception to this is if ARM beads are applied to the top and bottom of long parts such as ripper tips. If the upper and lower heat-affected zone depths are greater than two-fifths (40%) of the total tip cross-section area, tip breakage may occur. This is a result of small cracks that occur in the ARM bead, and the gaps between the particles and weld pool. Cracks travel easier through areas with higher concentrations of stress raisers. Also note that base metal cracking may result from the ARM operation if ARM is applied to any components that have high hardness (approximately Rockwell "C" 50 and higher).
During ARM work on warm days, make sure air movement from open shop doors or ventilation fans does not blow the shielding gas away from the arc. Also, if your shop is located in a warm, humid climate and morning water condensation occurs, make sure the particles, as well as the wire and GET tips, are completely dry before starting. This prevents piecepart cracking due to hydrogen. The hopper should be emptied at the end of the day, or an incandescent light can be positioned close above the particle hopper and left on, to help keep the particles dry. A small mirror can also be positioned close to the light, to conveniently check hopper capacity from the floor.
Miscellaneous Information
If ARM is to be added to miscellaneous ground engaging tools at the request of a customer, more ARM is not always better. It is possible to "over carbide", thereby winding up with parts that are fully worn but still have considerable carbide remaining in areas of low material contact. Inspect parts that have been used in the machines application. Used parts will show material flow patterns. These indicate where ARM beads will be most effective, and will provide the best return for the customers investment. Also, piling ARM beads on top of each other is not recommended, since the carbide in the lower bead will melt and produce too hard a deposit. Some outside shops perform ARM using Nickel/Chrome hardfacing wires, to add wear resistance to the weld bead itself. Although this may be beneficial in some applications, Caterpillar has not done research in this procedure because of the added cost of these types of wire.
Production Costs
It is difficult to establish an exact production rate for applying ARM because of the many variables, but a starting estimate is 740 cm/hr (115 in/hr), running a 2.5 cm (1.0 inch) bead width. The overall rate of usage for hard particles is approximately 2.3 g/cm (.50 ounce/in.). There can be many other items to be taken into account in determining the final cost, including the degree of piecepart cleaning required, any pre-bending or heating, and if it is necessary to re-paint the finished tips. An estimate of application cost for a given part can be made by filling out copies of Tables 5 through 8.
If further information is needed concerning the setup, application, and costs of ARM, contact any of the following:

The Product Support Representative of your marketing organization GET group hotline
Page 23 of 25
Caterpillar Dealer Support
Caterpillar Dealer Support may be contacted at (309) 675-8263. The GET hotline is (800) 422-8438.
Variable Cost Calculations Tables for the Welding Procedure

Table 5 Average Arc Time (Minutes) Net Cost of Dealer for Carbide
Weld Traverse Speed (inch/min.)
Pounds of Carbide That Was Purchased
Weld Width (inches)
Cost per 60 lb Spool of Welding Wire
Wire Feed Speed (inch/min.)
Price of Shielding Gas
Weight of 6 feet of Welding Wire (lb)
Cubic Feet of Shielding Gas
Flow Rate of Shielding Gas (cu.ft./hr.)
Electrical Cost (dollars per kilowatt hour)
Voltage Setting
Welders Hourly Labor Rate
Amperage of Welder
Laborers Hourly Rate
Table 6
Page 24 of 25
Average Work Cycle Welding Time Time (minutes) Time of Labor Time (minutes)
Welding
average arc time
General (1)
1.5 times the average arc tim
Back Travel
1/5 of average arc time
Gather, Clean Excess Particles Clean Nozzle
of average arc time
1/5 of average arc time
Fill the Hopper
1/20 of average arc time 1/20 of average arc time 1.5 factor of average arc time
Fixture Set up
Time Needed for Loading and Unloading the Part Straightening
This is not required for short parts. Total Time (minutes)
Total Time (minutes)
(1)
The General Section is used to cover other miscellaneous costs that have not been accounted for, including changing consumables, cleaning parts, any clamping or preheating, and repainting if needed. Table 7
Intermediate Calculations Average Arc Time (hours) Carbide Factors Factors of Welding Wire
Dollars per Pound
Dollars per Pound
Average Weld Pass
Pounds per Hour
Average Weld Pass
Square Inch of Weld per Average Arc Time
Factors for Shielding Gas Dollars per Cubic Feet
Factors for Electricity
Kilowatts
Average Weld Pass
Kilowatt hours
Dollars per Average W Pass
Table 8
Calculations for Cost
Page 25 of 25
Labor Cost
Cost of Material
Total Variable Cost
Variable Cost per Square Inch
Note: The variable Cost Calculations Tables do not consider fixed costs. For example, the costs for equipment, weld tables and development of fixtures.
Copyright 1993 - 2010 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.
Wed Dec 1 13:53:20 EST 2010

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Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Pautas de reutilizacin y recuperacin

Application of Abrasion-Resistant Material

SEBF8782 August 2002 SMCS Codes: 0679, 0751

GUIDELINE FOR PRODUCT UPDATE Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Illustration 1 A.R.M. Equipment

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

U.S. Dept. of Labor Washington, D.C. 20210

Illustration 2 Vibratory Particle Feeder

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Illustration 3 Water Cooled Torch and Particle Feed Tube

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Illustration 4 Table for Welding Equipment

Illustration 5 Screen Mesh Sieves

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Illustration 6 Control Panel for A.R.M. Equipment

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Sources of welding helmets are: Hornell, Inc. 2374 Edison Blvd.

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Basic ARM Welding Process

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Spray vs. Globular Transfer

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Sketches of spray and globular transfer

Basic Weld Parameters for ARM

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Welding Parameters Number____________

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Type of Welding Wire

Wire Feed Rate

Width of Weld Bead

Height of Weld Bead

Setting of Carbide Feed Machine Carbide Feed Rate

Dwell of Oscillation (Right and Left)

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Sample Setup Parameters Initial Settings

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

280 146 mm/min (5.75 in/min) 889 cm/min (350 in/min)

320 152 mm/min (6 in/min) 457 cm/min (180 in/min)

380 203 mm/min (8 in/min) 292 cm/min (115 in/min)

460 305 mm/min (12 in/min) 279 cm/min (110 in/min)

Evaluating Quality of ARM Beads

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Specifics for Caterpillar Parts

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Bsqueda del medio - SEBF8782 - Application of Abrasion-Resistant Material

Caterpillar Dealer Support

Variable Cost Calculations Tables for the Welding Procedure

Weld Traverse Speed (inch/min.)

Pounds of Carbide That Was Purchased

Weld Width (inches)

Cost per 60 lb Spool of Welding Wire

Wire Feed Speed (inch/min.)

Price of Shielding Gas

Weight of 6 feet of Welding Wire (lb)

Cubic Feet of Shielding Gas