BELZONA TAKES A GOOD HAMMERING

KHIA ID: 4721
Industry: Steel & Metal Processing (STEL)
Application: ENC-Engines and Casings (ENC)
Substrate: Cast iron
Customer Location: Foundry, Teesside, UK
Application Date: 2013
Products:

Belzona® 1221 (Super E Metal) 

Belzona® 1321 (Ceramic S-Metal)

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.
Photograph Descriptions
  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
Application Situation
2,500 tonne forging press.
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.
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