I.  DESCRIPTION AND APPLICATIONS:

A specially formulated hard-surfacing welding electrode specially for sugar mill machinery and allied equipment.  The electrode is iron based alloyed with manganese, chromium and carbon.  Most ideal for rebuilding of sugar cane mill rolls and other wearing parts of sugar mill equipment.  Excellent for high impact and high temperature applications under corrosive medium.

The electrode deposits hard alloy under ionic arc transference which turns the teeth of the mill rolls to a high wear resistance protuberances, protecting the mill rolls against heavy abrasive wear by the cane during milling.  This process increase sugar production up to 50%  and reduces wear up to 300%

Sucroweld 80 is a unique electrode that can deposit even if the mill rolls are in motion.  The electrode keeps depositing in the presence of sugar can juices and baggase.

II.  TYPICAL CHEMICAL COMPOSITION OF ALL WELD METAL DEPOSITS(%)

III.  TYPICAL WELD METAL HARDNESS AS WELDED ON MILD STEEL                                                        

IV.  RECOMMENDED CURRENT:

SPECIAL FEATURES AND BENEFITS

Deposits a wear resistant deposit for greater life with less need for touch-up. May be applied in both wet and dry conditions, thus reducing the need for costly maintenance stoppages. Dramatically increases cane feed rates and therefore improves production. Is less costly than carbon-arc roughening and eliminates the need for chevrons. Increases the surface area, and thus the pressure, giving lower levels of moisture in the bagasse. Is a manual metal arc electrode which can be used on AC or DC + thus eliminating the need for additional or expensive semi-automatic equipment.Requires only low operator skills without any special training.  Semi-skilled staff can, therefore, be utilized.

APPLICATION:

Uses of  SUCROWELD 80 are not limited to mill rolls.  The weld metal is resistant to abrasion even under conditions where medium impact loads occur.  Shredder hammers, chain links, cane handling equipment, for example, can all benefit from the hardness and impact resistant of  SUCROWELD 80.

WELDING PROCEDURE WITH SUCROWELD 80

SUCROWELD 80 has been specifically designed for surfacing sugar mill feed rolls in both wet and dry conditions.

SUCROWELD 80 is applied to the rolls during maintenance periods when the mill is free from cane, when it is either running or stationary.  Mill rotational speed during surfacing can be between 2 and 5 r.p.m., the ideal  being 3 r.p.m.  The greater the rotational speed, the smaller the amount of weld metal that will adhere to the roll.  When surfaced dry the globules have a diameter of approximately 4mm and closer control of coverage can be obtained.

In many instances sugar production at a mill is the primary consideration and only short periods of maintenance are possible.  Where these conditions occur, the welding electrodes may be used with a holder, which has a handle length of approximately 1,6 mm.  Normally a beam is provides on which to rest the holder to reduce operator fatigue.  The globules deposited when welding in the wet state are generally finer than those deposited dry i.e. 2mm. To further reduce wear of rolls the apex of the teeth can be surfaced with a 4mm electrodes.  The rolls should, however, be stationary to obtain a conventional weld bead.   

The life of the SUCROWELD 80 deposit, as one may expect, is dependent upon a number of factors i.e.

(I)    the fibre content of the cane

(ii)   the cane cutting procedure i.e. manual or automated

(iii)  environmental conditions during cutting i.e. wet or dry

(iv)  the type of soil

TYPICAL CURRENT VALUES

Diameter mm                                                    3.20                 4.00

Current A                                                     100-140            140-180

Polarity                                                          DC + AC 70 OCV min.

When roller arcing is carried out in the wet condition a welding current of 180-200 should be used.

DEPOSITION DATA

Note:  The deposition data given was established at the optimum current rating which would be approximately in the middle of the range specified

Diameter (mm)                                     3.20                 4.00
Length mm                                            350                  350
Burn-off time sec                                  125                  195
Mass of metal
deposited/electrode(g)                        36.6                    75.9
Weld metal
deposited/arc hour(g)                            1334                2791
Number of electrodes
/kg of weld metal                                  28                    13
Kg weld metal/kg        
electrodes                                            0.73                 0.73

Approximately 7 to 9 electrodes are required to surface one tooth.  The sides of the tooth are surfacedfirst.  Two electrodes are usually required for the top of the tooth.

PACKING DATA
DIA. Æmm                                                 3.2                       4.0
LENGTH mm                                           350                       350
No. of pcs./kg                                              19                        13