Welding Repairs of Fatigue Failure, Damaged Cast, and Corrosion Service
JW Portable Welding & Repairs has built upon advanced technology of welding repairs, damaged cast welding and corrosion service. Our customers demanded from us an advanced technology and we have responded positively to their demands. Our repairs using advanced welding technology or advanced epoxy technology have increased our comparative advantage and our geographical reach.
The advanced technologies of welding and industrial corrosion services are not provided by local mobile welders. Therefore our clients rely on our repair services. Although, we have never revealed our trade secrets gained through capital investment in technology, here you will find some interesting details. The description of our comparative advantage attracts also our new clients.
Advanced welding technology for metal fatigue failure
Our mobile welding service offers advanced technology of welding repairs related to metal fatigue failure commonly known as cracks. The mobile welding service offers:
- on site aluminum cracks repair,
- steel cracks repair and
- stainless-steel cracks repair.
These cracks can happen due to excessive vibration or impact on heavy machinery or on heavy equipment. You can also find them on steel structural elements or on metal casts.
Advanced welding rods and wires
Our visitations to welding shows in North America have helped us to develop selection of welding rods and wires more suitable for performing the crack repairs. These cracks can be found on welds or on metal and they indicate severe structural integrity damage.
Our own improvements of welding repairs
We have also improved our preheating process delivery prior welding and its monitoring. Our asymmetrical welds improve the weld resistance to excessive vibration. The asymmetrical heat distribution during welding process corrects mechanical alignment of cracked components. We have also developed unique shape of "fish plate" that increases some joint resistance to vibration.
Preheating and root penetration
We begin with monitoring the heat during the preheating. Then we continue the heat monitoring during the welding process itself since each type of metal requires different procedures in this regard.
We begin welding with selected root penetrating rods or wires according to selected welding technique to deliver the filler metal. Mild steel, stainless steel and aluminum require different welding technology for delivery of filler metal for the root penetration. They also require adjusted welding technique pending the type of rod or wire.
Prior root preparation, we tend to consider joint modification and groove modification in order to to achieve the more vibration resistant weld. Understanding the forces acted on the broken joint helps us to modify the joint in order to increase its strength. An engineering and millwrighting background and long experience in repairs of such damages is very helpful.
For deposition of groove filler, a different welding rod or wire is selected. We could also use a different welding technology to increase efficiency of the whole process. By increasing efficiency we must not sacrificed quality. The potential damages can occur due to excessive heat accumulation and then excessive cooling. Excessive heat accumulation and excessive cooling could cause weld cracks, material cracks and warpage. Excessive heat can cause even a complete material disintegration as it is in case of aluminum. The heat dispersion techniques on stainless steel could eliminate extreme temperature’s amplitudes and assists in avoiding inadvertent damages due to excessive warpage.
Welding a “Fish Plate”
The whole welding repair process ends with welding a “fish plate” on top of the repaired crack. Many factors influence the “fish plate” shape, its thickness and its weld size. We have to consider the best way to protect the weak spot, strengthen the immediate area of the crack and relocate potential stress to different location. Once again, we could chose a different rod or a wire for welding in a “fish plate”. The irregular size of the weld will reflect our efforts to relocate the stress to different area.
We recommend comprehensive vibration analysis after extensive crack welding on the heavy machinery or heavy equipment, since the bearing tolerances could change due to micro-warpage.
Our advanced technology and comparative advantage of damaged cast welding
We are proud of our advanced technology and comparative advantage in mobile welding of damaged cast such as: steel cast, iron cast and aluminum cast. Welding damaged cast is difficult and expensive since it requires a very good welding machine, knowledgeable welder and proper welding rods or wires. Most welding repairs on damaged cast happens in the shop in a very controlled environment.
When sending the broken cast to the shop is technically impossible or impractical or too costly than our clients call us. With us on board, our clients avoid extensive disassembly and then assembly time, costly loading and unloading, and costly transportation to distant location. They avoid also risk associated with transporting the cracked cast. The cracked cast can sustain additional damages due to standard vibration or impact that occurs during transportation, loading and unloading.
We will weld, in place, their damaged casts such as steel cast, iron cast and aluminum cast. The ability to repair cracked and damaged casts, in place using our mobile welding services forms our comparative advantage and is a source of our greatest pride.
Our comparative advantage of on-site mechanical/welding re-fabrication
The mechanical and welding re-fabrication of tractor, skid steer, and excavator attachments or other equipment and machinery attachments forms our next significant comparative advantage. We specialize in significant modifications and re-fabs of the attachments performed on site with the continued access to the main machinery.
The uninterrupted access to the new equipment or new machinery allows us to precise match the old attachment to the new machine. During this modification and/or re-fabrication processes, we take multiple attempts to match the attachment to the new machinery or new equipment in order to assure of a perfect fit and attachment functionality.
Advanced technology of our industrial corrosion service
Our most advance technology refers to industrial corrosion service. Corrosion service includes steel corrosion service and aluminum corrosion service. We also provide advanced chemical corrosion service for most popular metals. Our initial investment in new epoxy metal testing and training have initiated a growing division of our industrial corrosion service.
For last 5 years we have accomplished many industrial corrosion projects. Each project aside of our traditional testing has contributed to a growing knowledge of this new and exiting epoxy metal material.
We begin the corrosion service with treatment of one of our rust converters. Then we attempt to rebuild damages caused by corrosion such as pitting, holes or replacement of the corroded fragment.
We use a combination of 24 different metal glues, epoxy potty, and variety of metal epoxies to rebuild the damaged surface. Our epoxy metal specialist rebuilds a damaged part layer by layer of custom made metal epoxy. During this rebuilding process we can increase chemical and impact resistance of the rebuild element.