Product category:
Fabrication Subcontracting Services
News Release from: Arc Energy Resources | Subject: Weld overlay cladding
Edited by the Manufacturingtalk Editorial
Team on 04 September 2003
Weld overlay reclaims mould turnover
rings
Forged rings that carry moulds in two automatic rollover machines are being reclaimed using weld overlay cladding that matches the materials specification of the original rings.
The Federal-Mogul Corporation plant at Lydney in Gloucestershire is a grey iron foundry specialising in the manufacture of chilled grey and ductile iron camshaft castings for automotive OEMs including Ford, Peugeot, Nissan, Rover and others around the world The plant produces around 100,000 camshafts each week
This article was originally published on Manufacturingtalk on 19 Aug 2003 at 8.00am (UK)
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The camshafts are cast in two-part moulds.
The top and bottom box moulds, which can weigh up to 500kg each, are produced on a BMD moulding plant.
Before casting, both halves are fed into an automatic cope and drag rollover machine that turns them face up for physical inspection.
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Every second box is then turned back to create a pair of moulds.
The forged rings that carry the moulds in two automatic rollover machines at the Federal Mogul plant have a framework on their inside diameters to which the boxes are bolted.
Their external diameters are driven by motors to turn the moulds through 180 deg.
When new, the surfaces of the rings are coated with an alloy that eventually wears away due to the backwards and forwards movement of the drive wheels.
If they are allowed to reach a point when they are no longer round they lose drive from the motor.
Says Federal Mogul Engineering Manager Chris Martin: "We operate two machines and hold spare rings for both.
As they are very expensive to replace and on long lead-times, we looked for an alternative to buying new rings.
A refurbishment programme, using weld overlay cladding specialist Arc Energy Resources, provided the answer." Rings are changed every two years.
Federal Mogul delivers the worn units to Arc Energy and collects them when they have been refurbished.
Explains Chris Martin: " Arc Energy's weld overlay cladding is absolutely first class, matching the precision and exact materials specification of the original rings, which ensures that we achieve comparable wear rates.
Turn round time isn't critical, which allows Arc Energy time to achieve the same high quality finish and precise tolerances of the original specification." He adds that by bringing the rings back to 'as new' condition Arc Energy also helps to achieve substantial savings on replacements and the waste cost of scrapping the worn rings.
Commenting for Arc Energy, sales manager Alan Brown says the rings, which are 1.4m in diameter and weigh approximately 400kg, are refurbished on special rigs that the company has designed and developed itself to handle a large variety of cladding projects.
"We carry out weld overlay cladding for many industry sectors, for example oil and gas exploration, where high levels of corrosion and wear are a problem.
As in this case, the experience enables us to offer the ideal technical and material combination for specific applications.".
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