Welding Alloys (WA)
Welding Alloys Consumables
Welding Alloys Group offer the world’s largest range of flux and metal cored welding wires for low, medium, high alloy hardfacing
and cladding applications, mild steel fabrication, also stainless steel, nickel and cobalt based wires using its own manufacturing
technology. The company also offers aluminium welding wires and covered electrodes. Advanced quality control systems
ensure consumables meet or exceed industry standards while complying with relevant international approvals.
WA unique expertise comes from years of commitment to research and the development of innovative, highly
specialised products and solutions designed to combat wear in a wide range of industrial applications.
Able to provide welding and technical support to industries requiring wear control and performance optimisation.
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Advanced welding consumables
Automated equipment for wear protection
Engineered wear protection solutions
/P>Applications for Thermal Power Plants
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• Base metal and coating thicknesses selected according to the application
• Choice of several coating types
• Preferred solution for maintenance
• Specially adapted for applications where weight is restricted
• Lighter and harder than comparable hard plates
• Advantageous for moving parts
• Designed for applications susceptible to a combination of wear and impact
• Ideal solution for material transfer and transportation areas
• Internally clad tubes to withstand high levels of abrasion
• Available in a range of internal diameters from 50mm
• Segmented elbow pipes easily changeable
• Customised diameters with maximum abrasion resistance
• Produced in our Integra shops
Fan Refurbishment
• Refurbishment in our Integra shops
• For an extended flue gas transport
• Reduced maintenance and less downtime by using WA cored wires and wear plates
• Base metal and coating thicknessesselected according to the application
• Choice of several coating types
• Preferred solution for maintenance
• Specially adapted for applications where weight is restricted
• Lighter and harder than comparable hard plates
• Advantageous for moving parts
• Designed for applications susceptible to a combination of wear and impact
• Ideal solution for material transfer and transportation areas
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WA Hardfacing Vertical Grinding Mills and Ball Race Mills
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• Supply of new preventively hardfaced advanced grinding components
• Hardfacing of worn castings back to the original component profile
• Refurbishment grinding of components within the local Integra Service Centre or in-situ
• Solutions for wear repair on a range of component including : separators, hot gas rings, casings, piping and dam rings
• Longer lifetime of refurbished components provides lower running costs
• Through our range of welding metal grades we offer the optimum cost benefi
Hardfacing
EN 14700 T ZFe HARDFACE FC-O
EN 14700 T Fe15 HARDFACE HC-O
EN 14700 T Fe15 HARDFACE CN-O
EN 14700 T Fe16 HARDFACE CV-O
EN 14700 T Fe16 HARDFACE CNV-O
EN 14700 T Fe20 HARDFACE STEELBCARBW
EN 14700 T Ni20 HARDFACE NiCARBW
EN 14700 T Fe8 HARDFACE TIC-O
EN 14700 T Fe10 HARDFACE 19 9 6
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Welding Alloys Industrial Applications
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Applications for Cement Plants
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WA GAMMA182
for heavy casting repairs (casting & forging) Advantages and benefit compared to stick electrodes:
• Welding time considerably reduced = 50% reduction of downtime
• 10-15% savings in material consumption
• Higher real ef iciency
• Welder appeal
• High mechanical properties
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WA Hardfacing Roller Presses
• Total engineering solution for repair of worn roller press grinding components
• In-situ operations or in our Integra Service Centre
• Supply of new advanced roller press grinding components
• Additional services: monitoring of the surface wear, application of chevrons or any specific geometry to increase efficiency
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WA Hardfacing Vertical Grinding Mills
• Supply of new preventively hardfaced advanced grinding components
• Hardfacing of worn castings back to the original component profile
• Refurbishment grinding of components within the local Integra Service Centre or in-situ
• Use of future-proof technology allowing continuous development in hard facing technology
• Application to several components: separator, hot gas ring, casing, piping anddam ring
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WA GAMMA182
for heavy casting repairs (casting & forging) Advantages and benefit compared to stick electrodes:
• Welding time considerably reduced = 50% reduction of downtime
• 10-15% savings in material consumption
• Higher real efficiency
• Welder appeal
• High mechanical properties
• Base metal and coating thicknessesselected according to the application
• Choice of several coating types
• Preferred solution for maintenance
• Specially adapted for applications where weight is restricted
• More adaptable, lighter and harder
• Advantageous for moving parts
• Designed for applications susceptible to a combination of wear and impact
• Ideal solution for material transfer and transportation areas
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WA 3-D Carb�?Wear protection Applications:
• Chutes
• Thick plates
Advantages:
• Increased productivity
• Fewer and shorter production stoppages
• Significant reduction in the cost of spare parts
• Elimination of intermediate and hazardous maintenance operations
• Increased lifetime, by at leas
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Applications for Hydropower
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WA Cored Wires
Martensitic stainless steels require special care during welding due to the risk of cold cracking.
Martensitic : Soft martensitic
Base material composition
FRANCIS Turbine type
Reaction turbine
PELTON Turbine type
Impulse turbine
KAPLAN Turbine type
Reaction turbine
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The benefits of Welding Alloys cored wire
Quality
• Very clean fusion and very good bead appearance.
• Virtually no spatter.
• Deposit soundness comparable to that of electrodes.
• Excellent mechanical and metallurgical properties.
Performance
• High deposition rates (kg/h), around three times greater than those of coated electrodes.
• Optimised arc time.
• High welding speed.
• The penetration characteristics lead to increase productivity.
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Hydropower Industry Welding Solutions
Turbines hardfacing protection.
CAVITALLOY is used for rebuilding hydro turbines when increased corrosion resistance and fatigue properties are required compared
to martensitic stainless steels or austenitic stainless steels of the 300 series.
CAVITALLOY deposit is a nitrogen strengthened austenitic stainless steel with superior cavitation resistance, comparable to that of
Co-base alloys.
Newly developed cored wire: CAVITALLOY
Welding Procedure
Welding Alloys your partner for cavitation protection
�?Elimination of the defect (grinding) and preparation of the
surface
�?Preheat to 150 °C
�?Buffer layer TETRA V 309L-G
�?Two layers CAVITALLOY
�?Post weld heat treatment not necessary
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Applications for Mining
Applications for Oil and Gas
Applications for Railways and Light Rail
Applications for Steel Industry
Classifier
Composite Wear Plates
Continuous Casting
Crusher
Hardlite™
Makuri Rotary Kiln Repair
Workshop and Plate Processing Manual
Application
• Agriculture
• Construction
• Recycling & waste treatment
• Power Generation
• Mining, ceramic & earth moving
• Steel
• Oil & Gas/Petrochemical
• Material handling & Transport
• Cement & building materials
• Defence
• Raw chemical
• Pulp and paper
• Glass industry
• Sugar