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Welding Shop

spray welding


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  #1  
Old 10-07-2014, 01:41:12 PM
wedge wedge is offline
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Default spray welding

I was told that it is possible to save an old crank journal by spray welding and grinding.What is this about?
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Old 10-07-2014, 02:37:41 PM
Rex Wellendorf Rex Wellendorf is offline
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Default Re: spray welding

Hi,That's true, it's done all the time. Most of the time it's a lot cheaper than a new part. It takes a lot of heat (torch), a lot of air and a lot metal powder.Rex.

Last edited by Rex Wellendorf; 10-07-2014 at 02:41:26 PM. Reason: Punctuation.
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Old 10-08-2014, 10:52:26 PM
Alastair Geddes. Alastair Geddes. is offline
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Default Re: spray welding

never seen it done but have seen the equipment, they use a arc plasma spray to do the welding.
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Old 10-16-2014, 09:07:53 PM
ttyR2 ttyR2 is offline
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Default Re: spray welding

Everything you wanted to know about the process: https://www.youtube.com/watch?v=KK9OwDxwJp4
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Old 10-16-2014, 10:33:08 PM
JonH JonH is offline
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Default Re: spray welding

The problem with spray welding is eventually the "weld" metal will flake off and wreck bearings. You don't actually have fusion of weld metal and base metal, just adhesion. In one of Wayne Grenning's threads about an engine he was restoring, he had a crankshaft built up with submerged arc. That produces a much better repair. Subarc puts much more heat into the part though, so a good stress relief procedure may be needed to minimize warping.

Good luck on your restoration.

Jon
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Old 10-17-2014, 09:11:02 AM
Ray Freeman Ray Freeman is online now
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Default Re: spray welding

Quote:
Originally Posted by JonH View Post
The problem with spray welding is eventually the "weld" metal will flake off and wreck bearings. You don't actually have fusion of weld metal and base metal, just adhesion. In one of Wayne Grenning's threads about an engine he was restoring, he had a crankshaft built up with submerged arc. That produces a much better repair. Subarc puts much more heat into the part though, so a good stress relief procedure may be needed to minimize warping.

Good luck on your restoration.

Jon
If Sprayarc is used correctly in an appropriate application it won't flake off. Its often used where fusion welding is not possible. Many metals such as alloy shafts or cast iron components can't be practically welded.The good thing about spray arc is you can apply many different metals,from white metal to stainless steel. We have often used it to build up pistons using aluminium bronze. Its been successful so far in all cases and can save having to sleeve an engine. We just bore it out to a cleanup and machine the piston to suit. The trick with the process is the pre machining. If its not right it will flake off.
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Old 04-21-2015, 10:44:22 PM
IronworkerFXR IronworkerFXR is offline
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Default Re: spray welding

spray arc is ok for a shaft that uses a bearing with its own race, any other crankshaft needs to built up with submerged arc .
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Old 04-22-2015, 01:17:13 PM
JonH JonH is offline
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Default Re: spray welding

Spray arc is a true welding process. If you watch the video in the link, that is neither spray arc nor welding for that matter. What he is doing is akin to placing your part behind a grinding wheel and showering it with sparks until it builds up to an acceptable size. The "filler metal" is not fused with the base metal, merely adhered to it. Spray arc is an extremely hot process where the base and filler metals are both melted and flowed together. That much heat in a part could severely affect the heat treat.

Jon
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Old 04-22-2015, 05:18:10 PM
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Brian Lynch Brian Lynch is offline
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Default Re: spray welding

We do this quite often where I work. We tear down large gearboxes, evaluate and rebuild them. Most of these units are in the 2 to 10 ton weight range. Usually on teardown we find the bearing journals have seen some wear from long service or neglect. Most of the pinions and lower speed shafts run in fluid film bearings that see rotational speeds from 1,000 to upwards of 12,000 RPM. We use a company out of Texas that does sterling quality work that is backed by a solid guarantee. I run the test floor at work. Believe me, I torture the piss out of things before they get shipped. I'd rather have a failure on my floor than at a customers business. Some of these boxes are components in a larger machine. Ha!, they might even be buried deep in the machine where getting to them is a task in itself. I've never seen a job from the company we use fail. A properly done HVOF Repair is as solid as the original dimension. We prove it through Magnaglow, Dye penetrant testing and inspection.
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Last edited by Brian Lynch; 04-22-2015 at 08:30:17 PM. Reason: spelling
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Old 06-23-2015, 03:22:28 PM
Seafarer12 Seafarer12 is offline
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Default Re: spray welding

They can do all kids of things. We had a thrust bearing on a turbine go out and the bearing was also the impeller of the shaft driven oil pump. It was a 6 month wait for GE to get a new one to us so we sent it off and got it built back up. It was pretty amazing since it was worn down to the blades of the impeller and there wasn't any metal there to begin with.

As far as the op with the crank journal. Why not just weld it up regular and machine it down? That sounds like the cheaper way to do it.
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