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Mining/Cement & Quarry Industries
礦業(yè)/水泥/采石業(yè)維護(hù)與維修解決方案

Impact and Abrasion - By nature one of the most demanding industries the maintenance engineer is likely to encounter. MWA International Ltd. has worked alongside the mining, cement & quarrying industries for many years gaining invaluable experience throughout various casting processes. From this we have developed a unique range of welding electrodes to combat the predominant wear elements found in your industry

沖擊和磨損 - 從本質(zhì)上講，這些是維護(hù)工程師可能會(huì)遇到的最苛刻的行業(yè)之一。MWA公司多年來一直與礦業(yè)/水泥/采石行業(yè)合作，在各種鑄造工藝中積累了寶貴的經(jīng)驗(yàn)?；诖?，我們開發(fā)了一系列獨(dú)特的電焊條，以對(duì)抗這些行業(yè)的主要磨損元素。

MWA International Ltd. - We have over 40 years experience working along side maintenance departments in all industries. Our aim is always to save companies money, we do this by reducing down-time and increasing the life of worn parts. This guide will isolate some of the more common problem areas within your industry, (see list below). Using our specialist knowledge we are able to provide a solution, minimising wear and in doing so generate large cost savings for your company.

MWA公司 - 我們?cè)谒行袠I(yè)的維修部門有超過40年的工作經(jīng)驗(yàn)。我們的目標(biāo)始終是為公司節(jié)省資金，我們通過減少停機(jī)時(shí)間和延長磨損部件的使用壽命來實(shí)現(xiàn)這一目標(biāo)。本指南將列出您所在行業(yè)中一些常見的問題領(lǐng)域（見下表）。利用我們的專業(yè)知識(shí)，我們能夠提供有針對(duì)性的解決方案，盡可能地減少磨損，從而為客戶節(jié)省大量成本。

Team Work - We look upon ourselves as an extension to your maintenance department or workshop. We try to understand your needs and adapt ourselves accordingly. We hope that by working together we can help improve the performance of your maintenance department and ultimately save you money.

團(tuán)隊(duì)合作 - 我們將自己視為客戶維護(hù)部門或車間的延伸。我們努力了解客戶的需求，并相應(yīng)地調(diào)整自己。我們希望通過共同努力，我們可以幫助客戶提高維護(hù)部門的績效，并最終為客戶節(jié)省資金。

Problems & Solutions

問題與解決方案

1. Mixer Blades, Scrapers, Shredders, etc., - Clay is extremely abrasive and will quickly wear away the bottoms and corners of most blades unless they are protected by a hard surface material. Designed to withstand severe abrasion, coupled with its ability to deposit large amounts of weld at low amperages, we would recommend our ‘375’ in the electric, gas or powder form.

攪拌機(jī)葉片、刮刀、粉碎機(jī)等 - 粘土具有極強(qiáng)的研磨性，會(huì)很快磨損大多數(shù)葉片的底部和拐角部位，除非它們受到堅(jiān)硬表面材料的保護(hù)。我們建議碳化鎢堆焊焊條MAC Tungsten E375，該款焊條設(shè)計(jì)用于承受嚴(yán)重磨損，在低電流下具有熔敷大量焊縫的能力。

2. Impeller Blades - The blades that make up the fan which draws hot gases etc. from the furnaces are subject to severe abrasion. These can easily be repaired with either Mac Trode E66 or Mac Hard E306 depending on the type of abrasion being encountered.

葉輪葉片 - 從熔爐中吸入熱氣等的風(fēng)扇的葉片受到嚴(yán)重磨損。根據(jù)磨損類型，可以使用鎳鉻合金特種鋼焊條Mac Trode E66或硬面堆焊焊條Mac Hard E306輕松修復(fù)。

3. Crushers (Primary & Secondary) - It is vital that while the weld deposit is abrasion resistant it is also able to yield slightly under impact. It is for this reason that a buttering layer of weld is applied prior to the hard facing material. This can be done using our Mac Trode E6130 on the first pass with either Mac Hard E306 or Mac Tungsten E375 on top (depending on the material being crushed).

破碎機(jī)（主級(jí)和次級(jí)） - 在熔敷層耐磨的同時(shí)，在沖擊下也能輕微屈服，這一點(diǎn)至關(guān)重要。正是由于這個(gè)原因，在堆焊之前，應(yīng)采用特種鋼焊條Mac Trode E6130作為緩沖層，再使用硬面堆焊焊條Mac Hard E306或Mac Tungsten E375（取決于母材）來堆焊。

4. Pumps (slurry etc.)  - Damage to pumps may occur both internally and externally. External damage usually consists of broken feet or cracks in the pump casing. Internal damage may be caused by the abrasive nature of the liquid being pumped. In either case repairs can be carried out quickly and cost effectively by your own maintenance staff using Mac Trode E66 and Mac Cast E407, depending on whether the base material is steel or cast iron.

泵（泥漿等） - 泵的損壞可能發(fā)生在內(nèi)部和外部。外部損壞通常包括支架斷裂或泵殼裂紋。泵送液體的研磨性可能會(huì)導(dǎo)致內(nèi)部損壞。在這兩種情況下，維修人員都可以使用鎳鉻合金特種鋼焊條Mac Trode E66和鑄鐵焊條Mac Cast E407快速、經(jīng)濟(jì)地進(jìn)行維修，具體取決于母材是鋼還是鑄鐵。

5. Kiln - Operating temperatures within kilns are often in the region of 1200°C. Due to the parent metal being under constant thermal cycling the weld areas are the most likely to fail. Therefore by using a special heat resistant electrode, Mac Stain E102, or an Inconel type electrode, Mac Nicro E213, this will combat the thermal cycling without failing.

爐窯 - 爐窯內(nèi)的工作溫度通常在1200°C范圍內(nèi)。由于母材處于恒定的熱循環(huán)中，焊接區(qū)域最有可能發(fā)生故障。因此，通過使用不銹鋼焊條Mac Stain E102(耐熱鋼型)或鎳合金焊條Mac Nicro E213(Inconel鉻鎳鐵合金型)，這將可以對(duì)抗熱循環(huán)而不會(huì)失效。

6. Kiln Drive - Kilns are supported by three spline mounted cast iron tyres some 16 feet in diameter. Cracking occurs in the weaker areas. Whilst this is an extensive repair, given the correct electrodes and procedures, an excellent cost effective repair can be achieved using our Mac Groove E71 and Mac Cast E407.

爐窯驅(qū)動(dòng)裝置 - 爐窯由三個(gè)花鍵安裝的鑄鐵輪箍支撐，直徑約16英尺。裂縫發(fā)生在較弱的區(qū)域。雖然這是一個(gè)廣泛的修復(fù)，但如果焊條和程序正確，使用我們的切割開槽焊條Mac Groove E71和鑄鐵焊條Mac Cast E407可以實(shí)現(xiàn)高成本效益的修復(fù)。

7. Conveyor Screws - The abrasive manner of many quarry products, i.e. stones and clays, causes wear along the leading edges and faces on conveyor screws. As this wear takes effect  the  conveyor becomes less efficient, it is at this stage that weld repair becomes a necessity. By using a buttering layer followed by a hard surface layer, conveyor screws may be reclaimed, in many cases the service life may be increased by as much as 300%.

輸送機(jī)螺桿 - 許多采石場(chǎng)產(chǎn)品比如石頭和粘土的研磨方式會(huì)導(dǎo)致輸送機(jī)螺桿前緣和表面磨損。隨著這種磨損的影響，輸送機(jī)的效率降低，在這一階段，需要進(jìn)行焊接修復(fù)。通過先使用一層緩沖層，再使用一層硬面層，可以修復(fù)輸送機(jī)螺桿，在許多情況下，使用壽命可提高300%。

8. Shafts - As with many industries, sub-contracting is the preferred option. This can prove to be both time consuming and expensive. Repairs may be done in house by use of either the correct grade electrode, Mac Trode E66, or by the most proficient process of Powder welding.

軸類 - 與許多行業(yè)一樣，一般是選擇修復(fù)外包。這可能既耗時(shí)又昂貴。修理可以在公司內(nèi)部采用正確等級(jí)的鎳鉻合金特種鋼焊條Mac Trode E66。

9. Hammers - Due to the severe impact and abrasive conditions which the hammers must withstand, it is essential that the mixture of weld deposited will protect the hammers without being too brittle. By using Mac Trode E6130 as a buttering layer, capped with either Mac Hard E306 or Mac Tungsten E375, the life of the hammers may be extended by 150%.

破碎錘 - 由于破碎錘必須遭受嚴(yán)重的沖擊和磨蝕，熔敷的焊縫混合物必須能夠保護(hù)破碎錘，而不會(huì)太脆。通過使用特種鋼焊條Mac Trode E6130作為緩沖層，用硬面堆焊焊條Mac Hard E306或碳化鎢硬面堆焊焊條Mac Tungsten E375覆蓋，錘子的壽命可延長150%。

10. Rotary Coolers - Any failures in this area of your plant will almost certainly be due to loss of corners on the coolers. They are usually of a high nickel content and are repaired using Mac Stain E101 etc.

旋轉(zhuǎn)冷卻器 - 冷卻器發(fā)生的任何故障幾乎肯定都是由于其拐角處缺失造成的。它們通常鎳含量較高，使用不銹鋼焊條Mac Stain E101等進(jìn)行修復(fù)。

11. Burner Nozzles - As with most areas within kilns, the requirement is for a heat resistant weld for temperatures in excess of 1200°c. By using either Mac Stain E102 or our range of ‘inconels’, repairs are long lasting and easily achieved.

燃燒器噴嘴 - 與窯內(nèi)的大多數(shù)區(qū)域一樣，要求在溫度超過1200°C的情況下進(jìn)行耐熱焊接。通過使用不銹鋼焊條Mac Stain E102(耐熱鋼型)或鎳合金焊條Mac Nicro E213(Inconel鉻鎳鐵合金型)，，可以實(shí)現(xiàn)持久且容易實(shí)現(xiàn)的修復(fù)。

12. Ball Mill - After the clinker has been conveyed to the cement mill it is ground in a tube mill filled with white cast iron balls. The inside of the mill is protected by hardened steel plates bolted in position. It is these bolt heads which need protection. This is achieved by using Mac Trode E6130.

球磨機(jī) - 熟料輸送至水泥磨機(jī)后，在充滿白口鑄鐵球的管磨機(jī)中進(jìn)行研磨。磨機(jī)內(nèi)部由螺栓連接固定的硬化鋼板保護(hù)。這些螺栓頭需要保護(hù)，可通過使用特種鋼焊條Mac Trode E6130實(shí)現(xiàn)的。

13. Clinker Inlet on Ball Mill - Usually Manganese castings. These are easily reclaimed using Mac Trode E6130 as a buttering layer. Mac Hard E306 as a hard surface material for ultimate abrasion resistance.

球磨機(jī)上的熟料入口 - 通常為錳鑄件。使用特種鋼焊條Mac Trode E6130作為緩沖層，可以輕松修復(fù)。硬面堆焊焊條Mac Hard E306是一種硬質(zhì)表面材料，具有優(yōu)異的耐磨性。

14. Ripper Teeth - Two possible failure modes are often the case when repairing ripper teeth.

General wear : It is necessary to give maximum abrasion resistance, for this reason we would use Mac Tungsten E375 for re - facing

Fatigue Failure : Due to the clawing action of the teeth they are subject to massive tensile and fatigue stresses. This is overcome by using Mac Trode E66 which gives a tensile strength of 55 Ton / Inch2.

斗齒 - 通常會(huì)出現(xiàn)兩種可能的失效模式：

一般磨損：有必要提供盡可能高的耐磨性，因此我們使用碳化鎢硬面堆焊焊條Mac Tungsten E375進(jìn)行重新表面處理。

疲勞失效：由于斗齒的挖掘動(dòng)作，會(huì)承受巨大的拉伸和疲勞應(yīng)力。使用鎳鉻合金特種鋼焊條Mac Trode E66可克服這一問題，其抗拉強(qiáng)度為840N/mm2。

15. Drive Housing - Often cast steel, on a repair we would be looking for a maximum strength and toughness. For these reasons Mac Trode E66 will give a permanent repair to this application.

驅(qū)動(dòng)器外殼 - 通常為鑄鋼，在維修時(shí)，我們會(huì)尋求強(qiáng)度和韌性。由于這些原因，鎳鉻合金特種鋼焊條Mac Trode E66將對(duì)該應(yīng)用進(jìn)行永久性修復(fù)。

16. Stabilising Arms - Again due to the huge stresses on the stabiliser arms, it is necessary to safeguard against future failure by providing the maximum possible strength. This is achieved by the use of Mac Trode E66.

穩(wěn)定臂 - 同樣由于穩(wěn)定臂上的巨大壓力，有必要通過提供盡可能大的強(qiáng)度來防止未來的故障。通過使用鎳鉻合金特種鋼焊條Mac Trode E66可以實(shí)現(xiàn)。

17. Augers - Augers are common in many areas of the construction industry. The majority of the wear occurs on the leading face or edges. These are easily reclaimed by either powder welding or electric welding using Mac Powder P306 / Mac Hard E306.

螺旋輸送器 - 螺旋輸送器在建筑行業(yè)的許多領(lǐng)域都很常見。大多數(shù)磨損發(fā)生在前緣或邊緣。使用硬面堆焊焊條Mac Hard E306進(jìn)行堆焊焊接，很容易修復(fù)這些部位。

18. Gear Teeth - The cost and lead times of replacing worn gears and sprockets is often beyond comprehension. It is with this in mind that MWA can offer you advice on which electrode and techniques to use depending on the grade of steel / iron of the component. It is not uncommon for a ￡10000.00 gear wheel to be recovered for a few hundred pounds.

輪齒 - 更換磨損的齒輪和鏈輪的成本和交付周期往往難以理解?？紤]到這一點(diǎn)，MWA可以根據(jù)部件的鋼/鐵等級(jí)，為您提供使用哪種焊條和方法的建議。一個(gè)價(jià)值10000.00英鎊的齒輪僅花幾百英鎊就能修復(fù)，這并不罕見。

19. Grinding Mill - Very similar to crushers except abrasion is now the key factor rather than impact. Mac Hard E306 / Mac Tungsten E375 will give an increase of 200% again.

磨機(jī) - 與破碎機(jī)非常相似，只是磨損現(xiàn)在是關(guān)鍵因素，而不是沖擊。使用硬面堆焊焊條Mac Hard E306/碳化鎢硬面堆焊焊條Mac Tungsten E375可增加使用壽命200%

20. Earthmoving Machinery - The weld repairs of earthmoving machinery is very diverse. It may involve hard facing of buckets and shovels. The ideal product to use for this would be Mac  Hard E335T. For the repair of cast iron components, i.e, manifolds, you would use Mac Cast E406. Stabiliser arms are a very common area of failure due to its high strength, to repair this you would  be advised to use Mac Trode E66. All of the aforementioned have been repaired using Mac Electrodes on many occasions. In addition to these there are many areas which are not so common and on which we will be able to advise you on, when and if the situation should arise.

土方機(jī)械 - 土方機(jī)械的焊接修復(fù)非常多樣化。這可能涉及鏟斗和鏟的硬面。理想的產(chǎn)品是碳化鎢硬面堆焊焊條Mac Hard E335T。對(duì)于鑄鐵部件（如歧管）的維修，可以使用鑄鐵焊條Mac Cast E405。由于其強(qiáng)度高，穩(wěn)定臂是一個(gè)非常常見的故障區(qū)域，要修復(fù)此故障，建議使用鎳鉻合金特種鋼焊條Mac Trode E66。上述所有設(shè)備都曾多次使用Mac系列焊條實(shí)現(xiàn)成功修復(fù)。除此之外，還有許多不太常見的領(lǐng)域，我們可以就這些領(lǐng)域向客戶提供建議。

21. Moulds - In brick and tile manufacturing, a chrome/nickel mould is often used to produce the finished item. It is important that the finished brick/tile is free from surface marks. Problems in this area often arise when the moulds become worn or pitted. Repairs can be made at this stage. However, we need to be ensuring that the weld deposit is not too hard otherwise the pitting would still occur. With this in mind, by using Mac Trode E66 which is also chrome/nickel based, we can achieve a mould and weld deposit which wear at approximately the same rate. Moulds can be recovered quickly and cost effectively.

模具 - 在磚瓦制造中，鉻/鎳模具通常用于生產(chǎn)成品。重要的是，成品磚/瓦不能有表面痕跡。當(dāng)模具磨損或凹陷時(shí)，這方面的問題經(jīng)常出現(xiàn)。在這個(gè)階段可以進(jìn)行維修。然而，我們需要確保熔敷層不是太硬，否則點(diǎn)蝕仍然會(huì)發(fā)生。考慮到這一點(diǎn)，通過使用同樣基于鉻/鎳的鎳鉻合金特種鋼焊條Mac Trode E66，我們可以獲得和模具磨損率大致相同的焊接熔敷層。模具可以快速、經(jīng)濟(jì)地修復(fù)。

22. Extrusion presses - When the clay is first processed through the extrusion press, wear occurs readily on the presses, which are often of a cast iron nature. Mac Cast E407 gives the maximum resistance to wear and cracking of our cast iron range and has been successful on this application many times.

擠壓機(jī) - 當(dāng)粘土初次通過擠壓機(jī)進(jìn)行加工時(shí)，壓力機(jī)上很容易發(fā)生磨損，這通常是鑄鐵性質(zhì)的。我們鑄鐵系列產(chǎn)品中鑄鐵焊條Mac Cast E407提供了盡可能強(qiáng)的耐磨性和抗裂性，并多次在該應(yīng)用中取得成功。

23. Chassis - Wear occurs through cracking and impact. By using Mac Trode E66 the part can easily be repaired.

底盤 - 磨損是通過開裂和沖擊產(chǎn)生的。通過使用鎳鉻合金特種鋼焊條Mac Trode E66，零件可以輕松修復(fù)。

24. Bearings - Like all bearing applications the wear is predominately caused through friction. They are usually phosphor bronze and therefore, by preheating to approximately 400°C and using either Mac Bronze E808 or Mac Bronze E809, an excellent repair can be achieved.

軸承 - 與所有軸承應(yīng)用一樣，磨損主要由摩擦引起。它們通常是磷青銅，因此，通過預(yù)熱到大約400°C，并使用銅合金焊條Mac Bronze E808或Mac Bronze E809，可以實(shí)現(xiàn)出色的修復(fù)。