large steel surface charging through welding process

Have you thought of metal deposition by spraying like as done by plasma coating?

Thicknesses can be controlled and the process is fast.

thank you for your answer ,

It seams to ft exactly my needs!

I no very little about charging, Could you tell me what metal I could deposit? what kind of welding it's called? I guess you meed a compressor and a heat source plus the metal in fine particle's. Am I correct

Issa,

I am not an authority on Plasma coatings and can not suggest the material to be used in your case but one of my friend can help you out. Reach him on his mail id abraham_koshy@hotmail.com

I do not know about your location but every country has guys who have this kind of set up and would gladly look in to your application.

Johnson

Hi capri,

Thanks for the info, but i would like to have more infos about the process and confirm that plasma welding can be used to fill a cavity up to 1/16 of an inch adding to the thickness of the steel. How does it compare to Tig welding for that purpose?

Issa

Perhaps you could look at electro-plating, or electroless nickel.

Both would give a thin, smooth buildup. Masking would be used for selective deposition.

For first part of your requirement , you can use plasma spray process with hydrogen gas and a suitable powder combination to meet requirements such as high hardness, resistance to friction, wear & tear abrasion etc. The spay is being done at a speed of one mach and above and the deposit thickness could be in microns. Any type of metallurgical combination to suit the base metal could be done. It will also meet your second requirement like filling up scratches and could be finished by grinding if required.

Alternatively variety of filler metals are available to suit the base metal and could be done using pulsed TIG welding. Pulsing will help to avoid overheating and helps to fill cavities, scratches etc. and could be finished by grinding. All these methods are generally available in all the countries.

Hi Sridar,

what I want to do is to fill (increase and odd shape like a bucket injection mold wall to up to 1/16 of and each to be added to the actual surface, so when injected he mold receive less plastics

Whats best Tig or Plasma

whats less expensive ? tig or plasma

What are the average cost for a plant machine tool shop? for Plasma and tig....do you know?

Does plasma require machining?

Thanks ,

Issa

May I interrupt?

You say "Upto 1/16" thickness buildup"

Means--- upto 1500 micrometer deposit

100 to 1500micrometer thickness--and scratches to be filled up too--very streamlined --- no more machining/grinding/lapping will be possible

No arc welding or Plasma spraying will give you the finish- predictably!

Your only way you can get Deposit AND Finish by is HARD CHROME PLATING. May take hours -but you can programme your work

Invest in a setup. You will need it all the time.

You also asked --What Steel should be used?

Answer-- any Carbon Steel plate that you can get will do .Preferably 0.3>0.5%C .

Thanks for your advice,

but is it not a more expensive way to charge a large metal plate surface than tig welding? I thought that at best one could deposit 5 thousand of an inch of chrome max!

than the finish should be perfect because Nickel hides defects but chrome magnifies them! Also chrome is not resilient to marks and grooves made by shock or scratches, because it is as rigid as the base metal being chromed, no more

Than you need several bath or one would suffice? with a lot of interrupted energy which is our daily sentence, us, the manufacturers in Haiti. And I don't believe that one would have time to switch to a generator for alternate energy supply without loosing the full process. So it should be done only powered by our own generator. than What would the voltage, and the amperage to know how big of a generator we would need?

Awaiting your interesting comment

Issa

Sorry if I kept you waiting.

Could not come into the CR4 earlier..

OK, you have some more material here which will make you more inclined towards buildind up with Hard Chrome:

Metallic Protectives Plating Hard Chrome

Functional or

hard chrome plating usually calls for deposit thickness in the range of 2.5 microns to 500 microns or more. The hard chrome deposit will have ...
www.metallichrom.co.uk/hardchrome.htm - 9

http://www.techmetals.com/EngineeredFinishes.asp

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For removing Scratches : You shouldinstall Electro-Chemical Machining setup. Before this get/study a small pocket book: ISBN 5-03 000082 -8 by Rumyantsev+Davydov

You might invest in Common High Current-Low DC volt installation covering both removing and deposition of metal.

Bottom Line- If a Die/Mould Costs $10,000 - you might recondition it to AS-NEW condition for $1000.

Welding & Plasma should not be written off either. They might save you in some situations.

Wish you good solutions.

MM

OOPS! Forgot about your BerylliumBronze buildup need.

The same Electroplating setup will do--with Beryllium Bronze finally over Base Copper and Nickel intermediate buildup coats.

Welding copper-beryllium can be very dangeous. Read the Meterial Safety Data Sheets before machining or welding beryllium. You can contact Brush Wellman Inc. for any safety concerns.

Hi,

WHEN ITS STAINLESS STEEL, WELDING, nothing works wonder as TIG. You can literally build a filler wire of the parent material from it self and build the cavities or blow holes of any small dimensions, so think of it.

thanks

RAJIV