KHIA headerKnow-How in Action

VOL XXVII, NO 105

Belzona® Takes A Good Hammering

 
 

Industry:

Steel (STEL)

 
 

Application:

Engines and Casings (ENC)

 
 

Customer Location:

Foundry, Teesside, UK

 
 

Application Date:

2013

 
 

Application Situation:

2,500 tonne forging press.

 
 

Problem:

Lower bolster was not held securely due to loose fixing bolts. This led to misaligned die sets as the press hammered out parts. The movement was so severe that nearly 100% of production on this press was considered scrap and the company were considering a very expensive replacement. In addition it was found that the walls of the threads were holed and welding was impossible.

 
 

Products:

Belzona® 1221 (Super E Metal) 

Belzona® 1321 (Ceramic S-Metal)

 

Substrate:

Cast iron

 
 

Application Method:

Application was then carried out in accordance with Belzona Know-How System Leaflet ENC-2 using Belzona® 1321 after first repiring holes in side of casting by bonding plates in place with Belzona® 1221.

 
 

Belzona Facts:

This emergency job took only 2 hours to complete with material costs of about £330. The press was back in full operation within 2 days, producing 200 castings an hour, 24/7. The customer has estimated production alone at over £38.4K per day. The repair lasted 112 days but by that time it had secured over £4.3M in production. The customer acknowledged that the cause of failure was not with the Belzona application and have since repeated the repair and stocks material for future repairs.

 
 

Photographs Description

  1. 2,500 tonne press in operation
  2. Damage to base thread walls
  3. Application of Belzona® 1321 to wet out threads
  4. All four bolts aligned with jigs whilst material cures
 
Case study pic one

 

 
 Case study pic two

 

 
 Case study pic three

 

 
 Case study pic four

 

 
 
For more information about Belzona visit: www.belzona.com