Bucyrus Welding Ecommendations

2 114 500 en - (02)
Published by:
Bucyrus HEX GmbH

Dept. 2470 Documentation
D-44149 Dortmund, Karl-Funke-Strae 36
Tel. +49 (0) 231 922-4340
Fax +49 (0) 231 922-5340
www.bucyrus-hex.com
TABLE OF CONTENTS
Foreword .................................................................................................................................. 1
Safety ........................................................................................................................................ 1
1.
Fundamentals
1.1
Loads on structural elements .............................................................................................................. 2
1.2
Types of loading .................................................................................................................................. 2
1.3
Material behaviour under different loads .............................................................................................. 4
1.4
Notches in components
1.5
2.
3.
1.4.1
Mechanical notches .............................................................................................................. 5
1.4.2
Metallurgical notches ............................................................................................................ 6
1.4.3
Shape-induced notches ........................................................................................................ 6
1.4.4
Notch effects ........................................................................................................................ 8
1.4.5
Practical experience ............................................................................................................ 9
Avoiding notches
1.5.1
Grinding drag lines ............................................................................................................ 10
1.5.2
Grinding tools .................................................................................................................... 10
1.5.3
Run-off tabs ........................................................................................................................ 11
1.5.4
Attaching auxiliary elements .............................................................................................. 12
1.5.5
Ends of ribs ........................................................................................................................ 13
1.5.6
Undisturbed flow of forces .................................................................................................. 13
1.5.7
Ribs and stiffeners .............................................................................................................. 14
1.5.8
Welding technique .............................................................................................................. 15
1.5.9
Welding of "tempering beads" ............................................................................................ 16
1.5.10
Buffering of weld edges ...................................................................................................... 16
1.5.11
Welding sequence .............................................................................................................. 17
Planning of repair and reinforcing work for steel components

2.1
Causes of damage ............................................................................................................................ 18
2.2
Preparatory measures ........................................................................................................................ 18
2.3
Scope of repair work

2.3.1
Scrapping of components .................................................................................................. 19
2.3.2
Temporary repair ................................................................................................................ 19
2.3.3
Permanent repair ................................................................................................................ 21
2.4
Precautionary examinations .............................................................................................................. 22
2.5
Detection of cracks and other defects

2.5.1
Examination for surface cracks with the dye-penetration test ............................................ 22
2.5.2
Examination for surface cracks with the magnetic powder test .......................................... 22
2.5.3
Ultrasonic testing ................................................................................................................ 22
2.5.4
O&K standards for testing procedures................................................................................ 22
Repair welding techniques

3.1
Gouging out and welding of cracks .................................................................................................... 23
3.2
Cracks in hub connections

3.2.1
Cracking along the center of the seam .............................................................................. 25
3.2.2
Sharp, exactly radial crack along the unchamfered edge .................................................. 26
TABLE OF CONTENTS
3.3
Welding on of a metal cylinder by the back-step technique................................................................ 27

3.3.1
3.4
3.5
3.6
Cracks in box-type sections................................................................................................................ 29

3.4.1
Opening of box-type sections ............................................................................................ 30
3.4.2
Removing parts of a chord plate by flame-cutting .............................................................. 30
3.4.3
Backing strips .................................................................................................................... 33
Recommended groove shapes for manual welding with electrodes

3.5.1
Butt joints ............................................................................................................................ 34
3.5.2
T-joints ................................................................................................................................ 35
WORKING SEQUENCE FOR WELD SEAMS

3.6.1
3.6.2
3.7
4.
Butt welds .......................................................................................................................... 36

3.6.1.1
V-butt weld........................................................................................................ 36
3.6.1.2
Double-V butt weld .......................................................................................... 36
3.6.1.3
V-butt weld with backing strip .......................................................................... 37
T-joint.................................................................................................................................. 37
3.6.2.1
T-joints (fig. 53), accessible from 2 sides ........................................................ 37
3.6.2.2
T-joints with backing strip (fig. 54), accessible from 1 side .............................. 37
Closing of working openings, renewal of component areas

3.7.1
Closing a working opening ................................................................................................ 38
3.7.2
Closing a web-plate opening .............................................................................................. 39
3.7.3
Replacing a chord-plate section ........................................................................................ 42

3.7.3.1
Salient chord plate ............................................................................................ 42
3.7.3.2
Recessed chord plate ...................................................................................... 45
3.7.3.3
Possible causes of damage to chord plates .................................................... 47
3.7.3.4
Repair of a boom with a salient chord .............................................................. 48
Reinforcing of steel components

4.1
5.
Working sequence .............................................................................................................. 27
Reinforcing plates
4.1.1
Dimensions ........................................................................................................................ 49
4.1.2
Shapes of reinforcing plates .............................................................................................. 51
4.1.3
Welding slots ...................................................................................................................... 52
4.1.4
Fitting of reinforcing plates.................................................................................................. 53
4.1.5
Weld seams of T-joints ...................................................................................................... 53
4.2
Shaping plates for repairs .................................................................................................................. 54
4.3
Reinforcing by shape improvements

4.3.1
End of ribs .......................................................................................................................... 55
4.3.2
Open sections/closed sections .......................................................................................... 55
4.3.3
Reinforcing by build-up welding .......................................................................................... 56
4.3.4
Improvement of curved sections in ribs .............................................................................. 57
Materials, filler metals for welding

5.1
Materials in welded components ........................................................................................................ 58

5.1.1
5.2
O&K component materials .................................................................................................. 59
Filler metals for O&K welded components depending on partner materials

and welding techniques ...................................................................................................................... 62
TABLE OF CONTENTS
6.
Heat treatment of materials

6.1
Preheating for tacking, welding, gouging and flame-cutting .............................................................. 64
6.2
Hot bending of plates ........................................................................................................................ 69
6.3
Hot straightening of plates .................................................................................................................. 69
6.4
Stress-relief annealing of steel components ...................................................................................... 69
6.5
Stress-relieving of steel components

6.5.1
Warming of components .................................................................................................... 70
6.5.2
Peening of weld seams ...................................................................................................... 70

6.5.2.1
Method of peening ............................................................................................ 70
6.5.2.2
Peening tools .................................................................................................... 71
6.6
Treatment of filler metals .................................................................................................................... 72
6.7
Temperature monitoring .................................................................................................................... 72
7.
Cold bending of plates .................................................................................................. 73
8.
Build-up welding
8.1
9.
Addition of missing / worn-out material

8.1.1
Build-up welding in drill holes ............................................................................................ 74
8.1.2
Build-up welding on worn-out threads ................................................................................ 75
8.2
Correcting of component shapes to improve the flow of forces .......................................................... 76
8.3
Build-up welding as a protection against wear .................................................................................. 76
Wear protection (hard-facing)

9.1
Fundamentals .................................................................................................................................... 77
9.2
Build-up welding of wear protection layers ........................................................................................ 77
9.3
9.4
9.2.1
Build-up welding patterns .................................................................................................. 78
9.2.2
Special hints ...................................................................................................................... 79
Filler metals
9.3.1
For buffer layers ................................................................................................................ 79
9.3.2
For hard-facing layers ........................................................................................................ 79
Repair of build-up welds

9.4.1
State of wear ...................................................................................................................... 80
9.4.2
Identification of buffer and hard-facing layers .................................................................... 81
9.5
Repair of cracks in build-up welds ...................................................................................................... 82
9.6
Welding on wear-resistant steel plates or steel strips
9.7
9.6.1
Arrangement of plates/strips .............................................................................................. 83
9.6.2
Bending of strips ................................................................................................................ 87
9.6.3
Working instructions .......................................................................................................... 87
9.6.4
Filler metals ........................................................................................................................ 87
Welding of plates or strips with wear-resistant coatings

9.7.1
9.8
Welding of wear-resistant studs

9.8.1
TABLE OF CONTENTS
9.9
Welding cutting edges onto digging tools of excavators

9.9.1
Working sequence .............................................................................................................. 90
9.9.2
Welding sequence (fig. 39) and filler metals ...................................................................... 90
10. Repair of cast-iron components by welding

10.1 Spheroidal-graphite cast iron
10.1.1
Hot welding ........................................................................................................................ 92
10.1.2
Cold welding ...................................................................................................................... 92
10.2 Flaky-graphite cast iron

10.2.1
Hot welding ........................................................................................................................ 93
10.2.2
Cold welding ...................................................................................................................... 93
10.2.3
Repair of components with the "interlock" technique .......................................................... 94
11. Touching up paint coatings in repair areas ................................................................ 95
Appendix
Comparison: old designation - new designation ................................................................ 96
Part nos. for filler metals........................................................................................................ 96
Conversion from foot (Fu) and inch (Zoll) to metric measure .......................................... 99
Conversion for units of length .............................................................................................. 99
Temperature units and conversion formulas ...................................................................... 100
Hardness - strength comparisen ........................................................................................ 101
GENERAL
Foreword
Safety
In spite of proper design, perfect stress analysis,

meticulous manufacturing, attentive maintenance and
responsible operation, damage to parts of building
machines and mobile industrial handling equipment
cannot always be completely avoided. Normal wear
in areas subject to mecanical or abrasive action must
always be reckoned with.
Always observe the accident prevention rules and

safety regulations.
Experience in the early detection of damage and the

causes thereof, the choice of appropriate repair measures and consistent, workmanlike execution contribute to a high availability of construction machines.
Before beginning with welding, gouging, hot and cold

bending and heat treatments, the person in charge of
the repair must be familiar with the material of the
component.
The present Technical Handbook has been compiled
from many useful hints supplied by welding experts
as well as from experience gathered in the field of
welding. They contribute to the proper planning and
execution of repair and reinforcing work. It is taken
for granted that the personnel in charge of this work
possesses the required expert knowledge. Moreover,
it is important to take the particulars of the respective
case of damage into consideration.
This latest edition of the Technical Handbook "Welding for maintenance and repair" SN 2 114 500.00 is a
revised and updated version and takes account of
EN standards. Some sections have been supplemented or added. For this reason, only the instructions in
this edition should be observed for welding work.
Work on recipients containing or having contained substances
that are combustible or susceptible to stimulate combustion,

that may be the cause of explosions and
which develop noxious gases, fumes, mists or
dusts during handling
must only be carried out under expert supervision and by experienced and specially qualified
persons.
Depressurize all circuits and components (e.g.
pipelines, coolers, hydraulic oil tank, compressed-air receivers) before opening them.
For fitting and removing of working equipment or
of components thereof, or for fitting and removing of units
make sure that the machine and its equipment

are secured against unintentional and unauthorized starting. Place the working equipment on the ground so that it cannot move
when mechanical or hydraulical connections
are opened or released.
make sure that equipment or components to

be fitted, removed or brought into another position are secured against unintentional moving, sliding or dropping by means of lifting
tackle or suitable suspensions and supports.
Persons working at a considerable height must

be equipped with a safety harness to prevent
them from falling.
If - for the execution of work - helpers, such as
marshallers, are needed, it is essential to fix the
responsibilities of the individual helpers beforehand and to observe these responsibilities during
the work in order to avoid any conflict of competence in safety matters.
Make sure that all tools, lifting appliances, sling
gear, supports and other auxiliary devices are in
a safe and reliable state of operation.
For further hints see para. 2.2 "Preparatory measures".
2 en - (0)
Page 1
FUNDAMENTALS
1.
1.1
Fundamentals
Loads on structural elements
Structural elements may be subject to different loads.
1.2
Types of loading
Loads (tension and compression forces) may act

upon the structural element as static or mainly static
(fig. 2), pulsating (fig. 3) or alternating loads (fig. 4).
Pulsating and alternating loads may occur either as
continuous or as shock loads.
Forces practically never act as individual forces but

mostly in combination (fig. 1).
Fig. 2
O
O
+F
Tension
-F
Compression
Fig. 1
Loads on structural elements produced by forces acting simultaneously and from different directions are
difficult to assess by computation.
Fig. 3
Modern computing methods nevertheless permit the

determination of stress magnitudes and concentrations.
Fig. 4
2 en - (0)
FUNDAMENTALS
The following illustrations (figs. 5 and 6) give an

example of different types of loads acting on the
boom of an excavator. The boom is stressed for
tension.
During the "digging" cycle, the boom stretches

out. The lower chord plate is subject to tension
and the upper chord plate to compression.
During the "lifting" cycle, the boom is compressed.

Now, the upper chord plate is subject to tension
and the lower chord plate to compression.
This means that the loads act alternately on the

boom.
Fig. 5
Fig. 6
2 en - (0)
Page 3
FUNDAMENTALS
1.3
Material behaviour under different loads
The mechanical stresses admissible with regard to

the operating safety of a structural element (N/mm2)
vary for the same material under static and alternating loads (fig. 7).
The reason for this material behaviour lies in the

gradual weakening of the cohesive forces along the
grain boundaries, and, at a later stage, in the occurrence and increase of disturbances in the microstructure (fig. 8).
Fig. 8
Shows an idealized material microstructure under

alternating load. The material experiences elastic
deformation along the sliding planes at the grain
boundaries. The sliding planes present no disturbances.
Permanent elastic deformation leads to shifting

of material grains along the sliding planes where
the first disturbances appear.
The disturbed areas widen as the frequency of

elastic deformation increases.
Fig. 7
The admissible mechanical stresses are clearly below

the values for tensile strength indicated in the standards. The example shows a rolled steel EN 10025 S355J2G3, with thicknesses >
_ 3 mm <
_ 100 mm.
2 en - (0)
FUNDAMENTALS
1.4
Notches in components
All areas where the ideal flow of forces in a component is disturbed are qualified as notches.
These notches may, however, also have other mechanical causes (fig. 10 and 11), such as:
steel stamping figures, chisel marks,
marking tool lines, damage by lifting
chains.
From their occurrence and their effect on the component 3 different types of notches have to be considered:
-
1.4.1
mechanical notches
metallurgical notches
shape-induced notches
Mechanical notches
Mechanical notches may occur during welding in the

weld seam (fig. 9).
Fig. 10
Fig. 11
Steel stamping figures
Chisel marks
Marking tool lines
Notches due to lifting chains
Fig. 9
Undercut
Incomplete joint penetration
Porosities in the weld deposit
Incomplete fusion
Grinding drag lines
Drop-through at the root
Underbead crack
2 en - (0)
Page 5
FUNDAMENTALS
Mechanical notches lead to stress concentrations (fig.
12).
Due to their properties, these areas, however small

they may be, show a different behaviour under loading which, in turn, leads to elongation impediments
and material constraints.
The occurrence of metallurgical notches can be kept
to an acceptably low level by applying optimized
welding and heat-treatment techniques.
The effect of existing metallurgical notches, e.g.
those produced by improper welding, can also be
mitigated by a stress-relieving and annealing procedure.
1.4.3
Fig. 12
Inadequate penetration of root
Incomplete fusion
These, in turn, lead to an enlargement of the

notches.
This procedure may repeat itself and eventually lead
to fracturing of the component.
Mechanical notches are mainly produced during the
manufacture, but later on also during the utilization of
the machine (traces resulting from use).
Mechanical notches can be detected by visual inspection or by non-destructive testing and then be
repaired.
1.4.2
Shape-induced notches
Shape-induced notches depend on the structural design and lead to stress concentrations caused by the
diversion of lines of forces (fig. 14).
In many cases, shape-induced notches are moreover
located in heat affected zones with metallurgical
notches.
Shape-induced notches can be largely reduced by
choosing an appropriate design. For all practical purposes, they have to be reduced to such an extent
that the negative influence exerted by them on the
endurance strength of the structural element remains
insignificant.
Metallurgical notches
Metallurgical notches are caused by thermal influence

on the material; i.e. always at or around weld deposits (fig. 13).
Fig. 13
The heat applied by welding leads to zones presenting different metallurgical and mechano-technological
properties depending on their distance to the heat
source.
Fig. 14
+ 2
Hardness distribution curve
Shape-induced notches can be subsequently

eliminated by changes in shape.
2 en - (0)
FUNDAMENTALS
Examples (fig. 15):
a + b: inadequately executed butt-weld joints between structural elements of different thicknesses.
c: better joint.
An ideal and yet cost-saving solution for the distribution of forces is the butt-weld joint where the plate
thickness difference is reduced by chamfering in a
1:4 ratio (fig. 16).
For relatively small thickness variations of the two

plates, the joint such as realized in example c) can
be sufficient.
Fig. 16
The forces should be able to flow as disturbance-free

as possible through the part of the structural element
that can be analysed.
Lines of forces should not, however, traverse auxiliary elements (fig. 17).
Fig. 15
Fig. 17
The welds used for fastening such auxiliary elements

are mostly overestimated as they cannot absorb the
forces prevailing in components
2 en - (0)
7
FUNDAMENTALS
1.4.4
Notch effects
Depending on their shape, notches have different

notch or influencing factors.
Possible notches (mechanical and metallurgical) in

the seams of butt-weld joints:
The influence of notch factors on the fatigue strength

of a component is shown in the graph (fig. 18).
For a notch factor of "O", practically the only effects

to be expected are from metallurgical notches.
Fig. 18
Location and shape of curves W, O, 1, 2, 3 and 4

refer to:
material:
EN 10025: S355J2G3
no. of load cycles:
2 10 6 (2 million)
i.e. of high fatigue strength
group of stress intensities: small, medium and high

stresses with approx. the
same frequency
2 en - (0)
FUNDAMENTALS
1.4.5
Practical experience
In order to lower the weight of components, designers often resort to materials with higher strength
values and to plates of lower thicknesses with no
changes to the shape of the component.
In this respect it should not be overlooked, however,
that the stability of the structural element only depends on the geometrical dimensions and the
modulus of elasticity E of the material. E is basically
the same for an S690Q and an S355J2G3.
This means that a component consisting of thinner
plates is subject to stronger deformations and thus
loses some of its service properties. Moreover, the
effects of notches on the strength of the materials are
increased.
High-strength fine-grained structural steels such as
S690Q offer advantages over ordinary fine-grained
structural steel S355J2G3 only in cases of static or
predominantly static loading and reduced notching
(fig. 19).
With the strength of the material increasing, the susceptibility of structural steel elements to notching becomes greater.
For machines subject to alternating loads and
equipped with notched structural steel elements it is
therefore recommended to use an S355J2G3.
Fig. 19
In this context, notches resulting from marks left by

usage have to be considered as well.
material:
S355J2G3, S690Q
no. of load cycles:
>
_ 2 10 6 (2 million)
Location and shape of curves W, O and 4 refer to:
group of stress intensities: small, medium and high

stresses with approx. the
same frequency
2 en - (0)
Page 9
FUNDAMENTALS
1.5.2
1.5
If notches in a component are avoided altogether or if

their acuity (notch factor) is reduced, the admissible
stresses
(N/mm2) can be increased.
In such case, the life of the component increases and
damages can be largely avoided.
1.5.1
Grinding tools
Avoiding notches
Grinding wheel on angle grinder (fig. 21):
Only suitable for the rough removal of material.
Not suitable for low-notch finish with controlled
direction of grinding grooves.
Grinding drag lines
Grinding grooves transverse to the main direction

of load are dangerous mechanical notches.
Grinding grooves transverse to the direction of loading
(fig. 20) should therefore be avoided during grinding.
Fig. 21
Grinding stone (fig. 22):

Suitable for grinding of weld surfaces, weld
ends and plate edges. Should be used at least
for finishing.
Fig. 22
Fig. 20
This rule cannot be observed if grinding wheels are

used for the work. Under these circumstances, manual reworking with emery paper may be required.
It is therefore recommended to use grinding stones at
least for the finishing pass.
10
2 en - (0)
FUNDAMENTALS
1.5.3
Grinding stone (fig. 23):
Suitable for grinding in component areas of
difficult access.
Run-off tabs
Mechanical stresses reach their highest value at the

edges of components.
Defects in the weld which are caused, for instance,
by arc strikes or end-of-weld craters in edge zones
should be avoided. The welding groove must be
completely filled along the edges of components.
Fig. 23
Steel milling cutter (fig. 24):

Suitable for rounding off small radii.
Fig. 25
For this purpose, the weld seam has to be extended

by ca. 50 mm using run-off tabs (fig. 25). In this
case, arc strikes and end-of-weld craters are located
in the extended part of the groove.
The cross-section of the run-off tabs used depends
on the shape of the welding groove.
Fig. 24
After welding, the run-off sections are to be removed

by flame-cutting and the surfaces to be finished by
proper grinding.
For such work, the grinding instructions given under
1.5. 1 should be followed.
2 en - (0)
Page 11
FUNDAMENTALS
1.5.4
Attaching auxiliary elements
To protect the base element it may be required to

work out alternative methods of fastening (fig. 28).
For the fastening of auxiliary elements no welding

should be carried out in the edge zones of structural
elements subject to high stresses.
The welds should end at a well-defined distance from
the edge of the component.
Arc strikes and end-of-weld craters should be located
as far away from the component edge as possible
(figs. 26 und 27).
Fig. 28
Examples:
Fig. 26
Fastening of pipe clamps on a very small base

element.
Stirrups for pipes, lamps, cables and similar fixtures fastened without welding on the highly
stressed bottom chord.
Fig. 27
12
2 en - (0)
FUNDAMENTALS
1.5.5
Ends of ribs
The ends of ribs on highly stressed structural elements must taper off "gently" and be surrounded by a
boxing weld.
1.5.6
Undisturbed flow of forces
Auxiliary elements - in this case a crane eye - must

be shaped in such a way that the lines of force are
not disturbed or even interrupted.
Fig. 30
Interruptions in the flow of forces produce stress

concentrations and lead to cracks (fig. 31).
Fig. 29
The welder must position himself and the component

in such a way that the boxing weld can be carried
out without arc strikes and end-of-weld craters.
The weld interface areas must be absolutely free
from notches. This can only be achieved by grinding
(fig. 30).
Fig. 31
Recommendation: Cut off the eyes after assembly.

Grind the surfaces smooth and
clean.
2 en - (0)
Page 13
FUNDAMENTALS
1.5.7
Ribs and stiffeners
Ribs, stiffeners and similar parts on components must

be welded with endless seams if the components are
subject to pulsating or alternating loads (fig. 32).
Fig. 32
Interruptions in the weld seams are not recommended, even if they facilitate the assembly of the component (fig. 33).
Tri-directional states of stresses in weld-seam crossings are considerably less dangerous for the
structural elements than defective or even missing
boxing welds in the gaps. They represent potential
starting points for fatigue fractures. Too large gaps
may lead to damage by "softening-up" the component
corner, even if the weld is otherwise faultless.
14
Fig. 33
2 en - (0)
FUNDAMENTALS
1.5.8
Welding technique
The effects of metallurgical notches can be considerably alleviated by applying a proper handling technique during welding.
Maximum bead or pass widths:

Solid wire:
Wire
0,8
1,0
1,2
1,6
When repairing components by welding, the stringer

bead technique must be used (fig. 34).
Width
8,0
10,0
12,0
16,0
Rod electrodes:
Rod
3,2
4,0
5,5
Width
8,0
10,0
12,0
The weld start points for multipass welding must run

in terraces (fig. 35) or cascades (fig. 36). This is
essential if faults due to arc strikes or end craters are
to be avoided on one line in the various passes.
Illustrations:
Fig. 34
The advantages of the stringer bead technique are:
Reduced heat input (joule/cm) per welding bead.

The heat-affected zone (HAZ) in the base material
remains very narrow, resulting in a metallurgical
notch with minimum notch action.
Heat input: (J/cm) = I x U x 60
v
I = current intensity (A)
U = voltage (V)
v = welding velocity (cm/min)
Each welding bead is tempered by the overwelding with the next bead.
The weld pool can be well controlled, with
good penetration at the weld edges,
avoidance of weld pool pre-flow (cold welding),
avoidance of poor fusion.
Fig. 35
Fig. 36
2 en - (0)
Page 15
FUNDAMENTALS
1.5.9
Welding of "tempering beads"
The welding of "tempering beads" provides a substantial improvement in the mechanical-technological

characteristics of the weld metal both in the cover
pass and in the heat-affected zone (HAZ) close to
the surface.
Fig. 37
Explanations of Fig. 37:
1.5.10 Buffering of weld edges

The formation of heat-affected zones (HAZ) is vital to
the durability of the weld, especially when welding
materials with a high carbon equivalent.
The aim must be:
a narrow heat-affected zone (HAZ),
a minimum reduction in the strength of the material and of the heat-affected zone (HAZ),
a slight increase in hardness at the transition

between the heat-affected zone and the base material.
This aim is largely achieved by so-called buffering of

the weld edges prior to weld- joining.
For buffering purposes, welding is done with the lowest possible heat input (J/cm).
The following details must be observed when buffering:
Weld the buffering with rod electrodes of the type

suited to the base material.
Beads 6 and 7 are the "tempering beads".
The welding of beads 6 and 7 re-heats the weld

metal of beads 1 and 3 / 4 and 2 respectively.
The metal is tempered.
Diameter of rod electrodes: 3.2 mm.
Preheat the base material, depending on type.
In this tempered weld metal, an ideal material

structure with improved expansion and toughness
characteristics is induced with a negligible loss of
strength.
Weld in stringer bead technique.
Check the inter-pass temperature of the materials

accordingly.
If necessary, the cover pass can be ground down.
If run-off tabs are present at the weld ends: buffer

beyond the start point as far as the end of the
run-off tabs.
Clean the finished buffering thoroughly before

overwelding. (Slag residues on the contact line
from one bead to the next).
Start the weld-joining without intermediate cooling

of the component.
When 2 separate components or fragments are to be

joined by welding, buffering should be done prior to
assembly in the most favourable welding position for
both parts.
Assembly of the warm parts must be scheduled before the heating, e.g. with an appropriate device.
16
2 en - (0)
FUNDAMENTALS
1.5.11 Welding sequence
Definition:
Stipulating in which direction a joint is to be welded
and in what sequence several joints are to be welded.
When welding weld crossings, the welding sequence

drawn below must be observed (fig. 38).
Explanation of drawing:
Presetting the welding sequence allows the following

to be determined:
The component must be kept as stress-relieved

as possible. Delays due to the effect of welding
stresses must be accepted.
The component must be kept as dimensionally

stable as possible. Intrinsic stresses in the component, resulting from the welding, must be accepted.
When repairing components by welding them, it will

generally be necessary to keep the component dimensionally stable.
2 en - (0)
Fig. 38
To avoid defects and thus to prevent mechanical

notches, weld crossings in the edge zone of components must not have any arc strikes or end craters.
Page 17
PLANNING OF REPAIR AND REINFORCING WORK

2.
Planning of repair and reinforcing

work for steel components
In planning the repair and reinforcement of steel

components, the first step should be to determine the
precise extent and the causes of damage and then to
fix and to carry out the appropriate measures.
Reinforcement without planning leads to new damage.
2.1
In practice, repair, reconstruction or reinforcing

work may only be carried out by experienced
welders. A welder holding a certificate in accordance with EN 287-1 135 P BW W03 t20 PC SS
mk already fulfils the basic qualification requirements.
If possible, welding is to be done in a workshop

which is equipped with the necessary tools and
lifting gear.
If welding work has to be carried out on site, the

component must be protected against atmospheric influences such as rain, snow, dew, wind, etc.
This can be achieved, for example, by a tarpaulin
used as a working tent.
Cleanliness at the place of work is of utmost

importance.
When dismantling the component, all built-on

parts, particularly those with articulations, must be
removed from the component.
Causes of damage
The causes of damage may be manifold.
Dimensioning errors
Incorrect estimation of the potential stresses and
load cases.
Dimensioning and design errors.
Unsuitable construction materials.
Manufacturing errors
Mechanical and metallurgical notches.
Measuring errors.
Mixing up of materials.
Material defects.
Hose and pipe connections opened in dismantling

the component as well as open holes and casings
should be closed carefully in order to prevent the
penetration of dirt.
The component to be repaired is to be cleaned

properly, particularly those parts of the component
on which work is to be carried out.
Weld grooves and surfaces for fillet welds must

be completely cleaned down to the bare metal.
Paint coatings and priming coats must not be

welded over.
Lubricants must be completely removed from

bearings in order to prevent them from liquefying
under the effect of heat and flowing into the weld
area.
Machined surfaces, pins, bearings, piston rods,

electrical components, etc. must be protected
against weld splashes and grinding dust by covering them with non-combustible materials.
Before carrying out welding on assemblies

containing electronic components, all connectors
must be unplugged.
Example: In hydraulic excavators equipped with
the PMS system, all connectors must be unplugged from the load-limit regulator (PMS box).
Prior to welding on components remaining on the

machine, the starter batteries must be disconnected. Disconnect first the negative and then the
positive terminal! After the work, reconnect first
the positive and then the negative terminal.
Before welding, the type and the properties of the

material involved must be determined.
Use only those weld filler metals that are suitable

for the base metal concerned.
Wrong operation of the machine

Wrong handling due to lack of experience.
Wrong use due to an overestimation of the machines capabilities.
Using the machine for activities for which it is has
not been designed.
(Example: Tri-Power pin and linkage).
Accidents
Accidents during transport, relocation or operation,
e.g. accidents caused by falling rocks when working in quarries.
2.2
Preparatory measures
To restore the machines availability independent of

the cause of damage, it is essential to fix the appropriate working procedure.
Important prerequisites for the execution of repair and
reinforcing work:
18
Repair, reconstruction or reinforcing work on

structural steel elements of construction machines
may be supervised only by experts with sufficient
experience in the design and construction of dynamically stressed components.
In cases of doubt, please address the O&K aftersales service which can refer the problem to the
respective specialized departments, if required.
2 en - (0)

2.3
Scope of repair work
The most suitable procedure to be followed in a case

of damage is shown in the diagram below.
After damage has been reported, one of the 3 following decisions is to be taken (fig. 1).
2.3.2
Temporary repair
The component must be repaired immediately in order to maintain the machines availability, e.g. because the machine is used for a job with fixed time
limits (fig. 2).
In spite of being a matter of urgency, temporary
repairs must nevertheless be performed carefully in
order to avoid new damage.
Fig. 1
2.3.1
Scrapping of components
The damage has reached such an advanced stage

that a proper repair is either technically no longer
feasible or linked with extremely high costs.
The limit for this decision is not a fixed one. Whereas
at home and in most industrialized countries the decision to scrap is taken relatively early, it may be
necessary in other countries to carry out the repair
because the procurement of a new part is difficult for
various reasons and sometimes even impossible. The
reasons for this situation may lie, for example, in the
lack of foreign exchange, in high customs duties,
long delivery periods and extended standstill periods
for the machine. Relatively low wage costs can also
be a reason in favour of the repair.
2 en - (0)
Fig. 2
Page 19

The following rules must be observed:
Cracks must be stopped by drilling when they are
still relatively short (fig. 3).
This measure ensures a reduction in the crack
propagation speed.
It does not, however, constitute a repair.
One possibility of finding the end of a crack consists

in non-destructive testing for cracks by means of one
of the well-known methods such as ultrasonic testing,
dye-penetration test, magnetic powder test or X-ray
testing.
After drilling, the stopper hole can be examined for
persisting cracks.
Long cracks should be immediately gouged out

and welded, even if the marginal conditions are
unfavourable.
The area of damage must be subjected to permanent

inspection. In case of a failure of the repair weld, the
measure described has to be repeated.
Fig. 3
It is particularly important to find the actual end of the

crack.
Depending on their starting point, cracks may traverse the component along curved lines (fig. 4).
Do not weld reinforcing elements onto damaged

areas. They not only make no sense, but moreover cover up the area of damage and make
permanent checking impossible.
Another possibility is that the area of damage may
widen and thus make proper repair at a later time
impossible.
Fig. 4
+ B
incorrectly stopped by drilling
20
correctly stopped by drilling
2 en - (0)

2.3.3
Permanent repair
A simple examination of the material consists

in comparing its hardness to that of known
materials.
The wall thickness of sheets, cast-steel or

forged pieces can be controlled and compared
to the dimensions contained in the drawings.
In case of persisting doubt, the component can

be subjected to a new analysis carried out by
a neutral institution.
In difficult cases, it is advisable to make use of

the services of a laboratory if, for example,
precise material analyses, hardness curves
and an appraisal of the materials microstructure and surface are required.
In certain cases, the expertise of an independent laboratory may also be required in order
to clear up liability matters.
In each phase of the work, all advantages at hand

should be made use of.
Fig. 5
Even so-called "trivial matters" may be of decisive

importance for the success of a repair.
If a decision in favour of a permanent repair of the

damaged component is taken (fig. 5), the following
rules are to be observed:
The repair work must be subject to supervision

and the phases in which inspections are to take
place be determined beforehand.
The cause of damage must be determined and

eliminated if it can be traced back to design or
manufacturing deficiencies. To determine the
cause of damage, the following simple measures
will often be sufficient:
-
Personal experience and comparison with

damage patterns in similar components.
Visual inspection of the area of damage with

the aim of finding the causes for the crack
starting point, such as mechanical notches,
missing weld seams, insufficient root penetration, etc.
A workmanlike repair giving a high fatigue

strength expectancy must be properly planned
and carefully executed on the workshop level.
Visual appraisal of the fractured surfaces with

the aim of finding the crack starting point by
means of the bench marks.
Moreover, the structure of the fractured surface allows conclusions to be drawn with regard to material quality.
2 en - (0)
It is advisable to explain the theoretical reasons

for the repair measure to the craftsman carrying
out the work as he will then develop a feeling of
responsibility for a successful achievement of the
repair.
In case of damage caused by design failures or

overloading, it may be necessary to reinforce the
component after the repair.
Important note: The reinforcement planned must
make sense and its positive effects be justified by
means of an analysis.
Badly planned reinforcing measures are useless,
expensive, do not offer real safety, increase the
weight of the component and may impede its
functions.
Moreover, they do not look very nice.
Page 21

2.4
Precautionary examinations
In the field of medical treatment, precautionary examinations are standard practice. Doctors teach us
that a disease, if discovered in its early stage, can be
cured by a simple operation, whereas in an advanced
stage, help often comes too late.
The regular inspection of construction machines, for
example, is also a kind of precautionary examination
and part of the VBG guideline 40.
Inspection procedure and follow-up measures:
4.
Spray white developer (O&K-SN 552 302) onto

the area.
Any cracks then become visible as small, red
lines on a white background. The extent of
"bleeding" and the waiting time allow conclusions
to be drawn as to the depth of the crack.
Wipe off the developer with a cleaning cloth.
2.5.2
Examination for surface cracks with the

magnetic powder test
The magnetic powder test is suitable for the detection

of cracks on the surface of the material and for
cracks not deeper than 2 mm below the surface.
Cleaning of the machine.
Visual inspection of critical component areas. Recording of all findings.
Contacting the manufacturer for a discussion of

the inspection results.
Planning and execution of necessary repairs.
2.5.3
Stockpiling of damage-prone components.
Stockpiling of wearing parts.
The ultrasonic test can be used for the detection of

defects inside materials of more then 10 mm thickness and in weld deposits.
Ultrasonic testing can only be performed by qualified
testers.
2.5
Detection of cracks and other defects
The component is first magnetized and then sprayed

with a liquid containing very fine iron particles (as fine
as dust). The iron particles settle along the cracks
and make them visible.
Ultrasonic testing
Qualification:
Certificates U 1 and U 2 of the

"Deutsche Gesellschaft zur zerstorungsfreien
Prufung"
(DGZFP)*.
Cracks and other defects in plates, forged and caststeel parts can be detected with the help of test
procedures:
2.5.4
2.5.1
Detailed information on testing procedures can be

found in the following O&K standards:
Examination for surface cracks with the

dye-penetration test
The dye-penetration test is the simplest procedure to

detect cracks in the surface of the material.
1.
Carefully clean the area to be tested.
2.
Spray red penetration fluid

(O&K-SN 1 044 915) onto the area and allow it
to take effect for 5 to 10 minutes.
3.
Remove red penetration fluid with a special

cleaner (O&K-SN 552 304).
O&K standards for testing procedures
07 47 04, part 1
Dye-penetration test, magnetic

powder test
07 47 01, sheet 1 Ultrasonic testing of welded

joints
07 47 01, sheet 2 Ultrasonic testing of cast-steel
and forged parts.
The O&K standards are available from O&K Dortmund, Standards Dept., in English or in German
(please state desired language).
* (German Society for Non-Destructive Testing)
22
2 en - (0)
REPAIR WELDING TECHNIQUES

3.
Repair welding techniques
The repair of a structural component by welding requires working methods which do not have to be
applied when the steel component is manufactured.
Many of the methods represented have been developed on the basis of numerous individual experiences and are field-proven.
3.1
Gouging out and welding of cracks
The method best suited for gouging out of cracks is

the so-called "ARC-AIR procedure" (fig. 1).
Fig. 2
Visible crack
Damage at the grain boundaries
If the crack is accessible from both sides in outof-position work, gouging should first start on the
lower side (fig. 3) with the depth of the groove being
approx. 1/3 of the material thickness.
Fig. 1
An arc is struck between a carbon electrode and the

material to be removed, and a jet of compressed air
directed towards the arc blows away the molten base
metal.
For part nos. of "ARC-AIR carbon electrodes" see
Appendix.
Another gouging method consists in gouging with
oxy-gas or with grooving electrodes.
It is important to start gouging at the end of the crack
and to proceed towards the edge of the component.
Proceeding in reverse order may enlarge the crack
due to thermal effects.
It can be taken for granted that the crack has already
progressed along the grain boundaries of the material
where it cannot yet be detected visually or by other
test procedures (fig. 2).
Gouging should therefore not start at the end of the
crack but shortly before the crack begins.
For gouging, preheat the cracked area (cf. 6.1).
After thermal gouging, the weld groove is to be reworked by grinding.
Fig. 3
Weld this side first.

The crack is then gouged out from the more easily
accessible upper side down to the seam already
welded from the lower side.
As a final step, the weld is finished on the upper side
(fig. 4).
The surfaces must be cleaned down to the bare

metal.
2 en - (0)
Page 23
If this procedure is not respected, it may happen that

areas of material between the cracks break away and
that the gaps thus produced cannot be closed.
The same applies to long cracks where gouging out
and welding should equally be done step by step.
(fig. 6).
Fig. 4
So-called "weld-pool backing strips" should not be

used if welding from both sides is possible, as a
backing strip in the root area of the weld represents
a mechanical notch (shape-induced notch).
Ramified cracks
Ramified cracks should be gouged out and welded
step by step (fig. 5).
Fig. 6
During cooling of the partial welds, the surrounding

cold areas prevent excessive welding shrinkage and
distortion of the component.
Fig. 5
24
2 en - (0)

3.2
Cracks in hub connections
Fig. 7 shows the connection of a hub to a box-type

section which is accessible only from one side.
A possible cause is a broken fillet-weld backing.

Counter-measures:
Gouge out the crack carefully (fig. 9).
Weld the gouged joint (fig. 10).
Gouge out the web plate (2) in the area of the
fillet-weld backing round the hub (1) and down to its
collar (fig. 10).
Weld the gouged joint (fig. 11).
Fig. 7
Hub
Web plate
Square-edge butt joint
Fillet-weld backing, welded before closing of the

box-type section.
Fig. 9
The weld is characterized by a fillet-weld backing on

the outer edge and the chamfered web plate.
The following defects may occur:
3.2.1
Cracking along the center of the seam (fig.

8)
Fig. 10
Fig. 11
Fig. 8
2 en - (0)
Page 25

3.2.2
Sharp, exactly radial crack along the unchamfered edge
A possible cause is a lack of fusion in the unchamfered edge of the joint (see arrow in fig. 12).
Fig. 14
Fig. 12
Counter-measures:
Gouge out the crack carefully (fig. 13).
Weld the gouged groove (fig. 14).
Fig. 13
26
2 en - (0)

3.3
Welding on of a metal cylinder by the

back-step technique
3.3.1
1.
The following example describes the welding of a

machined cylinder onto an undercarriage.
Working sequence
Position and align the cylinder in accordance

with the drawing. Tack the cylinder solidly on the
outside and carry out a dimensional check after
tacking.
Welding by the back-step technique can always be

employed where as distortion-free a weld as possible
is required.
This applies to circumferential seams as well as to
longitudinal seams.
Fig. 15 shows how to execute the weld between the
web plate of the cylinder and the base plate.
Fig. 17
2.
Welding of the 1st pass from the inner side of

the cylinder (fig. 17).
For this work use rod electrode 3.20 mm.
Weld in accordance with the back-step procedure,
step length: approx. 250 mm
Fig. 15
Outer side of cylinder
Inner side of cylinder
Fig. 18 shows an example for the back-step

technique.
Welding is carried out in the normal operating position.

Welding position: horizontal
Correct positioning of the electrodes avoids defects
from incomplete fusion (9, fig. 16) at the web plate
edges.
Fig. 18
Fig. 16
2 en - (0)
Page 27

3.
Grind weld joint clean working from the cylinder

outside. Remove any slag residues from the 1st
pass and completely grind out any cracked tack
welds.
5.
Complete the joint on the cylinder inside (fig. 20).

Rod electrode 5th and 6th pass:
4 or 5 mm.
Weld seams as described under 4.
Do not weld over cracked tack welds!
Fig. 20
Fig. 19
4.
Weld the full seam on the cylinder outside. The

example in fig. 19 shows a cylinder wall thickness of 15 mm. For other plate thicknesses, the
build-up of the weld has to be planned and
executed accordingly.
Rod electrode 2nd pass:
Rod electrode 3rd and 4th pass:
6.
6.1 There must be no undercuts, weld metal

pores, arc strikes, end craters, spatter particles, slag, etc.
6.2 Carry out a dye-penetration test of the surface which must be absolutely free from
cracks.
3.20 mm
4 or 5 mm
Weld all beads in the back-step procedure and

stagger starting and end points of each new
layer.
Clean the weld seams and check for defects.
7.
Check the dimensions. Irregularities in the plane

of the cylinder flange must not be levelled by the
application of heat (danger of distortion due to
weld-induced residual stresses).
Example:
28
2 en - (0)

3.4
Cracks in box-type sections
Gouging and welding of cracks only from the outside

cannot be recommended.
Welding without backing strips usually leads either to
an incomplete filling of the root area or to a dropthrough at the root (fig. 21).
Fig. 21
In both cases, the mechanical notches in the root

area will lead to the formation of new cracks.
Welding on backing strips introduced through the joint
can equally not be recommended (fig. 22).
Fig. 22
The backing strips will not come to rest properly on

the base metal.
Flashes and slag residues on the under-side cannot
be removed.
The resulting mechanical notches will cause new
damage.
2 en - (0)
Page 29

3.4.1
Opening of box-type sections
If the crack is accessible only from one side, an

access opening has to be created from the second
side. This can be done by opening the component in
areas not subject to high stresses (figs. 23 and 24).
Practical hint:
Ribs are often visible on the reverse side of the
plates.
Especially on painted surfaces they are clearly visible.
Gouge out the crack first from the inside (over 1/3 of
the plate thickness) and weld. Continue on the outside and then reclose the box-type section.
3.4.2
Removing parts of a chord plate by flamecutting
Figures 25 to 30 show how a box-type section can

be opened in a way which does not affect the
remaining parts of the component.
The section (1, fig. 25) of the top chord (2) is to be
removed.
Fig. 23
Fig. 25
Cut a pilot hole in the chord plate (2, fig. 26) behind
the web (3) with a flame (4). Flame-cut in longitudinal
direction and as closely as possible to the web plate.
Cutting must be carried out without producing drag
lines in the web plate.
Fig. 24
In larger components there may also be openings

allowing access to the interior of the component. The
size of access openings is approximately 500 mm x
500 mm.
If the internal structure of the component is unknown,
it is advisable to contact the design department.
A drawing showing the location of possibly existing
stiffening ribs inside the box-type section should be
at hand.
Otherwise it may be necessary to cut out small spyholes in order to find out the areas in which repair
openings of sufficient size can be created.
Fig. 26
30
2 en - (0)
Sever the remaining strip of the chord plate (5, fig.

27) by flame-cutting from the inside.
Fig. 27
Flame-cut the welding chamfer required for welding

the new chord plate section (fig. 28).
Cutting as in fig. 30 leads to unnecessary damage of

the web plate (3, fig. 30) (5 = damaged area /
flame-cut area).
Fig. 30
Welding on backing strips

Openings cut into components in order to gain access to the under-side during the welding of cracks
must be carefully reclosed in a workmanlike manner.
Welding of the component is carried out from one
side on backing strips (fig. 31).
Fig. 28
Make the transverse cut in the chord plate by proceeding from the web plate towards the center and
not - as shown in fig. 29 - from the center towards
the web plate (3).
Fig. 31
The geometry of the weld and the welding sequence

shown are to be carefully observed. Only then can a
welding seam with a relatively low root notch factor
be expected.
It goes without saying that the root notch factor of
such a welding seam has to be compatible with the
selected component area.
This must be examined before opening the component.
Fig. 29
2 en - (0)
Page 31
The same applies basically also to the welding of

T-joints (fig. 32).
Fig. 34
Fig. 32
The same working method can also be employed if

plates of different thicknesses are welded (figs. 33
and 34).
If the joint is larger than required, welding should

start with a build-up weld on one of the seam edges
in order to avoid excessive transverse shrinkage.
After depositing the build-up weld, the gap between
the seam edges can be completely closed (fig. 35).
The method shown in fig. 33 is, no doubt, the better

solution.
Chamfering of the thicker plate in a 1 : 4 ratio.
Fig. 33
The welding joint must in no case be too narrow, as

the planned welding sequence can otherwise not be
observed.
32
Fig. 35
This applies equally to the welding of T-joints with too

large a groove.
2 en - (0)

3.4.3
Backing strips
Backing strips are mostly made of flat steel 30 x 6 or

25 x 4 (fig. 36).
Fig. 37
Fig. 36
Backing strips for non-linear weld seams are flamecut out of plates with the corresponding thickness
(fig. 37) or welded together from pieces of flat steel
(fig. 38). The joints (fig. 38) must be welded and
ground from both sides.
Fig. 38
2 en - (0)
Page 33

3.5
Recommended groove shapes for manual

welding with electrodes
For repairs or welding work carried out in the field,

the following weld groove configurations should be
preferred.
These groove configurations can be employed for
plate thicknesses up to 30 mm. The dimensions
shown in the drawings are applicable up to this thickness.
For gas metal-arc welding, the weld preparation angle can be reduced to 45o.
For greater plate thicknesses, the weld preparation
angles must be reduced so as to leave a maximum
opening width of abt. 30 mm. Except for the sharpedge seam, all grooves should be gouged out,
ground and counter-welded, if possible.
3.5.1
Fig. 41
Butt joints
Recommended weld groove shapes:

-
V-butt weld (fig. 39)

Double-V butt weld (fig. 40)
Single-bevel butt weld (fig. 41)
Double-bevel butt weld (fig. 42)
Square-edge butt weld (fig. 43)
Fig. 42
Fig. 39
Fig. 43
Fig. 40
34
Welding
technique
Symbol
EN 24 063
Opening angle
111
60
MAGM
135
45
Solid wire
136
45
2 en - (0)

3.5.2
T-joints
Recommended weld groove shapes:

-
Single-bevel butt weld (fig. 44)

Double-bevel butt weld (fig. 45)
Square-edge butt weld (fig. 46)
Fig. 45
Fig. 44
Fig. 46
2 en - (0)
Page 35

3.6
WORKING SEQUENCE FOR WELD

SEAMS
3.6.1
Butt welds
easily accessible side
poorly accessible side
3.6.1.2 Double-V butt weld (fig. 49)

Seam accessible from 2 sides
3.6.1.1 V-butt weld (fig. 47)
Fig. 49
Joint prepared
Joint welded overhead
Root gouged out
Seam welded
Fig. 47
Joint prepared
Joint welded
Root gouged out from the under-side
Root capped
Double-V butt weld (fig. 50). Seam accessible

from 2 sides after turning of the component
V-butt weld (fig. 48). Seam accessible from 2

sides after turning of the component
Fig. 50
Fig. 48
Joint prepared
Joint welded
Plate turned, root gouged out
Root capped
36
Joint prepared
Root welded
Plate turned, root gouged out
Seam welded
2 en - (0)

3.6.1.3 V-butt weld with backing strip
3.6.2
T-joints
V-butt weld with backing strip 25x4 (fig. 51). Seam

accessible from 1 side
3.6.2.1 T-joints (fig. 53), accessible from 2 sides
Fig. 51
Fig. 53
Backing strip attached
Web and chord plates tacked
Joint prepared and 1st root bead welded
Single-bevel weld deposited
2nd root bead welded
Root gouged out
Seam welded
Seam welded
V-butt weld with backing strip 30x6 (fig. 52). Seam

accessible from 1 side
3.6.2.2 T-joints with backing strip (fig. 54), accessible from 1 side
Fig. 52
Fig. 54
Weld-backing strip attached
Backing strip welded
Joint prepared
1st root bead welded
Joint gouged out (grinding)
2nd root bead welded
Seam welded
Seam welded
2 en - (0)
Page 37

3.7
Closing of working openings, renewal of

component areas
Openings (fig. 55) should be as small as possible but

as large as necessary in order to allow the unimpeded use of tools.
Weld seams [2] and [3] alternately and use the socalled "back-step procedure" for the long seams.
Back-step welding:
Experience: Openings 300 mm long and 200 mm

high are normally sufficient.
3.7.1
Closing a working opening
Weld seam [4] in the same way as seam [1].
Fig. 55
The following example (fig. 55) is suitable for plate

thicknesses up to 25 mm.
Fig. 56 shows a backhoe stick. The diagram of moments clearly shows the areas of highest loads and
thus of greatest stresses. Seam [1] is therefore the
seam that lies in the area of high chord stresses.
Weld seam [1] from the middle outwards to the left
and right to the midpoint of the corner curvatures.
Finish upper beads or passes approximately 15 mm
before reaching the end of the underlying bead or
pass. Allow the completed weld seam to cool down
to approximately + 50oC.
38
Fig. 56
2 en - (0)

3.7.2
Closing a web-plate opening
Fig. 59
4.
Fig. 57
1.
At the web-plate (2, figs. 57 + 58), chamfer the

edges to be welded with approximately 10o.
Width b of the chamfer in reldition to the plate
thickness can be seen in fig. 70, page 42.
Prepare backing strip (3) from flat steel 30 x 4

bent on edge or burn out of 4 mm thick plate. Do
not tack-weld backing strips from flat-steel bars
for lack of cover at the rounded corners.
Attach backing strip (3) to the web plate (2) by
means of screw clamps (fig. 60). Do not tackweld but rather weld with a 3 mm fillet seam
running all around (fig. 61).
Fig. 60
After welding the fillet seam, clean the contact

surface for the cover plate by removing all traces
of weld spatter (arrow, fig. 61).
Fig. 58
2.
Gouge out the longitudinal seams between chord

plate (1) and web plate (2) over a distance of
approximately 100 mm (fig. 58).
3.
Attach backing strip (3, fig. 59), but only to the

web-plate edges.
Fig. 61
2 en - (0)
Page 39

5.
Prepare cover plate (5, fig. 62) for the repair

opening. For this purpose, use a new plate of
the same thickness and chamfer as shown.
Width (b) can be seen in fig. 70, page 42.
Fig. 62
6.
Attach cover plate (5, fig. 63) and check for

perfect weld joints.
The cover plate must be in full-face contact with
the backing strip.
In case of distortions due to welding, the backing
strip has to be straightened.
Press cover plate (5, fig. 64) against backing

strip by using screw clamps. In workshops, this
can be done with box-type section widths of up
to 1.5 m.
Fig. 64
If the use of screw clamps is not possible, the

cover plate should be fastened by so-called
"hold-down strips" (6, fig. 65). Attach the holddown strip (6) to the web plate (2) with a fillet
weld. Fix the cover plate (5) by driving wedges
(7) between plate and strip.
After welding of the cover plate, remove holddown strips by flame-cutting.
Grind welded areas smooth and clean.
Do not knock off hold-down strips with a hammer.
Fig. 63
Fig. 65
40
2 en - (0)

7.
Weld on cover plate (fig. 66).
Fig. 66
Fig. 67
It is essential to observe the welding sequence

shown. The symbols used have the following
meaning:
Weld seam [1] approximately to the midpoint of

the corner curvature. Place the first bead exactly
between cover plate (5) and backing strip (3).
The upper bead must end approximately 15 mm
before the end of the underlying bead. After
welding of seam [1], the cover plate may shrink.
Proceed by welding seams [2] and [3]. Make
sure that the seams interlock properly with the
ends of seam [1] (prepare by grinding). Weld the
other ends through to the chord plate. The end
of seams [2] and [3] at the chord plate are to be
ground as shown in fig. 66, so as to obtain the
same shape of the welding joint as the one
between web and cover plate.
Finish the sequence by welding seam [4]. The
ends of welds [2] and [3] must not come to lie
against interruptions or starting points of seam
[4]. If possible, weld seam [4] with continuous
stringer beads from one end to the other.
Finish by grinding the surfaces of seams [1], [2],
and [3] flush with the adjacent plates (fig. 67).
2 en - (0)
Page 41

3.7.3
Replacing a chord-plate section
1.
3.7.3.1 Salient chord plate
Chamfer welding bevels at 10o. Width b (fig. 69)

can be read from fig. 70 below.
PLATE THICKNESS t
CHAMFER WIDTH b
8
10
12
15
20
25
30
35
40
45
50
2,0
2,0
2,5
3,0
3,5
4,5
5,5
6,5
7,0
8,0
9,0
In a box-type section with 2 web plates (fig. 68), a

chord-plate section is to be replaced by a new one.
Fig. 70
2.
Work out the longitudinal seams between web

plate (2, figs. 68 + 69) and chord plate (1) over a
length of approximately 100 mm from the point
at which the new piece is to be fitted.
Fig. 68
Fig. 71
Fig. 69
42
2 en - (0)

3.
Attach backing strips (3, 4, figs. 72 + 73) at the

two remaining ends of the chord plate (1). Fit the
plates properly and without any gaps.
5.
Weld the backing strips (3, fig. 75) with fillet

seams to the web plates (2).
Fig. 75
Fig. 72
6.
Tack-weld backing strips (4, fig. 76) to the outer

side of web and chord plates.
Fig. 73
For the backing strips (3,4) use flat steel 25 x 4

mm. Fit backing strip (3) exactly between the
two web plates (2). Adapt external backing strips
(4) to the joints of the web plates (2) and allow
them to extend outwards by approximately
30 mm.
4.
Fig. 76
7.
Tack-weld run-off tabs (5, fig. 77) to backing

strips (4). Cf. also the section "Ends of butt
welds".
Tack-weld backing strips (3) between the web

plates. If distortion occurs due to welding (fig.
74), the backing strips have to be straightened.
Fig. 77
Fig. 74
2 en - (0)
Page 43

8.
Fit the new piece of chord plate (6, fig. 78). The
old piece of chord plate previously removed must
not be used again. Make sure that the new piece
of plate rests properly on its support.
10. Weld in the new piece of chord plate by strictly

observing the welding sequence shown (fig. 80).
The symbols have the following meaning:
Seam [1]
transverse seam in the area

subject to high chord-plate
stresses. Weld seam completely.
Seams [2] + [3]
weld longitudinal seams in

the direction indicated by
the arrows.
Seam [4]
weld transverse seam completely.
Seams [5] + [6]
weld longitudinal seams in

the direction indicated by
the arrows.
Fig. 78
9.
Weld the two fillet seams (fig. 79) as shown,

without interruptions and without any tack points.
Weld seams [1] and [4] with stringer beads and

continue the weld onto the 50 mm long run-off
tabs (4). Remove the run-off tabs after welding
with a clean cut.
Fig. 79
The surfaces of the transverse seams must be

ground clean and flush with the adjacent plates.
Work out properly the longitudinal seams in the
area of the transverse seams. The grinding drag
lines must run parallel to the longitudinal lines of
force. If possible, the transverse seams should
be subsequently subjected to ultrasonic testing.
Practical hint:
In welding the longitudinal seams [2] [3] [5] and
[6] there must be no welding starts or stops in
the area of the transverse seam (backing strip).
Fig. 80
44
2 en - (0)

3.7.3.2 Recessed chord plate
2.
The following example shows how to fit a new recessed piece of chord plate by welding it into a
box-type section with 2 web plates (fig. 81).
Work out longitudinal seams between web plate

(2, fig. 83) and chord plate (1) over a distance of
approximately 100 mm beyond the cutting edge
of the chord plate.
Fig. 83
Fig. 81
Working sequence:
3.
Attach backing strips (3, figs. 84 + 85) to the two

remaining ends of the chord plate (1).
For the backing strip (3) use flat steel 25 x 4
mm. Fit in backing strip (3) properly and without
any gaps between the two web plates (2).
Fig. 82
1.
Chamfer welding bevel at 15o. Width (b, fig. 82)

can be taken in fig. 70, page 42.
Fig. 84
2 en - (0)
Page 45

5.
Weld in new piece of chord plate by strictly

observing the welding sequence shown (fig. 87).
As to the welding of the seams, cf. 10 on page
44.
Fig. 85
4.
Tack backing strips (3) between the web plates

(fig. 85 + 86). If there is any distortion due to
welding, the backing strips have to be straightened.
Fig. 87
Fig. 86
46
2 en - (0)

3.7.3.3 Possible causes of damage to chord
plates
The following faults may occur in chord plates of
box-type sections:
1. Transverse cracking
The chord plate may crack open transverse to the
component in the chord plate.
Reason for the damage:

There are non-metallic inclusions from the pool (segregation defects), distributed over the entire plate
dimension, at the centre of the plate.
Measures:
The plate cannot be repaired by welding.
For durable repairs, the damaged plate must be replaced. It is to be assumed that areas of the plate
not yet cracked open would eventually also crack
open as a result of the dynamic stress on the component.
3. Longitudinal cracking
The chord plate may crack open in longitudinal direction of the component parallel to the edge of the
plate (fig. 90).
Fig. 88

Expansion of the component obstructed by non-optimally dimensioned or welded
component elements such as bearing blocks, ribs,
reinforcing plates etc.
Measures:
The component can almost always be repaired by
welding. For a durable repair, the component must
be opened to allow the welds in the component
areas subject to maximum stress to be capped.
2. Plate parting
The plate may crack open almost exactly at the
centre of the plate, as shown in the diagram (fig. 89).
Fig. 90

The component is not adequately stable. The chord
plate is deformed under changing loads, resulting in
material distortions at the weld/chord plate transition.
Measures:
The chord plate cannot be repaired by welding.
For a durable repair, the plate must be replaced in
the cracked area. The new plate must be thicker than
the cracked one to reduce deformation to a tolerable
level.
Fig. 89
2 en - (0)
Page 47

3.7.3.4 Repair of a boom with a salient chord
3.
The top chord of the boom is cracked (arrows,

fig. 91).
Repair the damage inside the box-type section

and in the side walls.
4.
Weld on new top chord (fig. 93). Increase plate

thickness by 5 to 10 mm.
1.
Remove support eye (1, fig. 91).
Fig. 93
Fig. 91
2.
Remove top chord in the area of damage

(fig. 92).
Recommendation: Remove the curved section of
the top chord completely.
5.
Weld support eye back in place (fig. 94).

Machining of the severed parts is generally not
required if fitting and welding are carried out
carefully.
Fig. 94
Fig. 92
48
2 en - (0)
REINFORCING OF STEEL COMPONENTS

4.
Reinforcing of steel components
The reinforcement of components by welding can be

done in the following ways:
Covering up a damaged area after repair by reinforcing plates, with the aim of reducing the mechanical stresses
(N/mm2) in the repair area.
Eliminating deficiencies caused by changes in

shape, e.g. the problematic case of "open sections/closed sections", shape of stiffening ribs,
configuration of frame corners, etc.
Thickness of reinforcing plates

The thickness of reinforcing plates should be max.
60 % of the thickness of the plate to be reinforced
(fig. 2).
Eliminating deficiencies by means of changes in

shape by build-up welding, e.g. on cast-steel
parts.
The necessity of a component reinforcement should,
if possible, have been proved by a simple analysis.
4.1
Reinforcing plates
Fig. 2
4.1.1 Dimensions
Length of reinforcing plates

The ends of reinforcing plates are places where
metallurgical and shape-induced notches occur
which may lead to damage by the concentration
of stresses (Part A, fig. 1).
An analysis shows that thicker reinforcing plates

cannot be connected to the plate to be reinforced
as the welding seams required would be too
large.
Thicker plates moreover lead to large shape-induced notches and make the component heavier
than is really necessary.
Width of reinforcing plates
In steel components, stresses are often highest
near the edges. The reinforcing plate should
therefore be as wide as the plate to be reinforced
(A, fig. 3).
Fig. 3
Fig. 1
Reinforcing plates should therefore be dimensioned in such a way that they end in areas with
low basic stresses (Part B, fig. 1).
2 en - (0)
Page 49

For practical reasons, reinforcing plates of less than
8 mm thickness can not be chamfered. In such
cases, the reinforcing plate (B, fig. 3) must be narrower to leave enough space for a fillet weld.
The upper edges (arrow, fig. 3) of the plate to be
reinforced and of the reinforcing plate should not be
melted away.
50
2 en - (0)

4.1.2
Shapes of reinforcing plates
Reinforcing plates should, if possible, have simple

shapes with straight edges (figs. 4 + 5).
To relieve the transverse seams of stresses, welding
slots should be provided (fig. 4).
Small plate strips, flat-steel or wide flat-steel bars,

can be more easily fitted and bent (fig. 5).
Fig. 6
Fig. 4
Another possibility consists in welding on strips of

plate. In this case, the longitudinal seams must be
welded continuously.
Non-linear plate shapes (figs. 7 + 8) are difficult to

manufacture and do not offer any advantages with
regard to the distribution of forces.
Advantages:
The edge zones, where high stresses normally prevail,
are reinforced. Another advantage is the reduction of
weight (fig. 5).
Fig. 7
Fig. 5
2 en - (0)
Page 51
Fig. 10
The welding seams in the welding slots are ideal

thrust connections between the reinforcing plate and
the plate to be reinforced.
Circular welding holes are disadvantageous (fig. 11):
Fig. 8
4.1.3
Welding slots
In addition to the welding seams along the outer

edges, the seams in welding slots are equally
intended to enhance the connection of reinforcing
plates (figs. 9 and 10).
Fig. 11
Fig. 9
Finish the ends of the slots by drilling stopper holes

(fig. 9).
Slot width = 2 x plate thickness (fig. 9).
The parts of the seam transverse to the lines of

forces cannot bear any loads and can therefore not
be considered for analysis.
The reinforcing plates cross-section is strongly reduced.
The hole edges are subject to stress concentrations.
52
2 en - (0)

4.1.4
Fitting of reinforcing plates
studs have been removed must be carefully prepared

by grinding before the slot is welded.
Reinforcing plates should be in full-face contact with

the plate to be reinforced, i.e. they should lie as
closely as possible against the base plate. The air
gap should, if possible, be nil.
For relatively small components and thin plates, the
reinforcing plates should be squeezed against the
base plate by means of screw clamps (fig. 12).
Fig. 12
For larger components and thicker plates, the

reinforcing plates should be held in place by wedges
(fig. 13).
This is, however, only possible at the edges of plates.
Welding and cutting of the wedge holders must be
done properly. Never knock off wedge holders with a
hammer.
Fig. 14
4.1.5
Weld seams of T-joints
Reinforcing plates in T-joint areas should be welded

in such a way that a connection between all 3 plates
is formed (fig. 15).
Fig. 13
The central area of plates can be pressed into position

by means of bolting (fig. 14).
This is particularly recommended for large plate
sections. The studs can be favourably placed near the
welding slots.
After tack-welding, the welded-on stud may only be
knocked off. The area in the base metal where the
2 en - (0)
Fig. 15
Page 53

4.2
Shaping plates for repairs
The plates needed for repair or reinforcement purposes can be shaped in different ways.
Problems which may arise in the different shaping
methods:
Edge folding (Fig. 16):
Rolling (Fig. 18):

cold shaping;
no problems to be expected after shaping.
cold shaping;
observe minimum bending radius;
watch for longitudinal cracking in the bending
area.
Fig. 18
Fig. 16
Multi-edge bending (Fig. 19):

cold shaping:
cracking at the lines where the tools act on the
plate edges is to be expected;
chamfer plate edges approx. 2 x 2 mm at top and
bottom after multi-edge bending.
Pressing (Fig. 17):

cold or warm shaping;
with cold shaping, observe minimum bending radius and watch for longitudinal cracking in the
bending area.
Fig. 19
Fig. 17
54
2 en - (0)

4.3
Reinforcing by shape improvements
4.3.1
End of ribs
Areas where overlapping takes place should be

ground smooth (fig. 21).
The terminal section of ribs ending on highly stressed

parts of components is to be shaped as shown in fig.
20. This applies equally to ribs of minor importance.
Fig. 21
Make sure that the welding seam as such is not

ground off.
4.3.2
Open sections/closed sections
The moment of torsion resistance of a closed section

is approximately 500 times greater than that of an
open section of otherwise similar dimensions.
This leads to stress peaks in the zone of transition
from the opened to the closed section. These peaks
are caused by deformation impediments and constraints (fig. 22).
Fig. 20
t
mm
a
mm
h
mm
R
mm
e
mm
L1
mm
L2
mm
10
60
20
30
12
10
60
20
30
12
10
10
80
20
30
12
12
10
100
20
40
14
15
10
120
30
50
18
20
12
10
160
30
60
22
26
12
10
180
30
70
22
30
10
15
10
200
30
70
28
Fig. 22
2 en - (0)
Torsional moment
Open section
Closed section
Page 55
Therefore, it is required to have a gradual transition

from the open to the closed section (fig. 23).
4.3.3
Reinforcing by build-up welding
The effects of notches in steel components can be

eliminated or at least mitigated by build-up welding.
Such work presupposes expert planning and careful
workmanship (fig. 24).
Fig. 23
The area of transition is to be welded around

continuously.
Fig. 24
56
2 en - (0)

4.3.4
Improvement of curved sections in ribs
Fig. 25 shows a rib contour with too high stresses in

the marked area.
Fig. 25
To improve this situation, weld on a plate of the

same thickness (fig. 26) and observe the welding
sequence as represented in the cross-section.
Subsequently, a new and better contour can be produced by flame-cutting (fig. 27). In doing so, make
sure that the torch guidance unit is absolutely stable.
Fig. 27
Flame-cut here
Grind flame-cut edge smooth and work out the new

contour (fig. 28).
Fig. 26
Weld joint prepared
Fig. 28
First side welded
Back of first side gouged to sound metal
Second side welded
Faces of welds ground smooth
2 en - (0)
Grind here
Reworking facilitates the gradual and continuous flow

of component forces.
Page 57
MATERIALS, FILLER METALS FOR WELDING

5.
Materials, filler metals for welding
5.1
Materials in welded components
Before welding, gouging, warm or cold bending and

heat treatments, the person carrying out the repair
must be familiar with the material of the component.
At least the following information should be available:
-
strength class
state of heat treatment
chemical analysis reference data; carbon
equivalent
material thicknesses
The repair measures to be carried out depend essentially on the above data.
The material properties cannot be determined by

simple hardness measurements or even by a
spark test. Such testing methods lead to wrong
conclusions.
After this, the filler metals suited to the materials can
be selected. For the selection of filler metals, the
person carrying out the repair should seek advice
from the manufacturer of the machine or the supplier
of filler metals. Recommendations can also be found
in the catalogues of the filler metal manufacturers.
The materials used by O&K for welded components
and their suitable filler metals are listed on the following pages.
These can be found in drawings and parts lists.

The operator of a machine can obtain the required
information from the manufacturer, e.g. from O&K.
In case of scheduled repair work, the type of material
can also be determined in a materials testing laboratory.
58
2 en - (0)

5.1.1
O&K component materials
Materials for welded components

in O&K construction machinery
and mining equipment
Plate
Plate
Standard designation:
Trade name:
Delivery specification:
EN 10025 - S275JRG2 (ex. St37-2)

-
EN 10025 - S355J2G3 (ex. St52-3)

LV 2 293 157
Description of material
Fine-grained structural steel

weldable
normalized
killed
Fine grained structural steel

weldable
normalized
double killed
Heat treatment state:
normalized or in an equivalent state attained by normalizing rolling
Mechanical and technological

properties (reference values):
Tensile strength
Hardness
Yield strength
Elongation
Impact energy
Rm
B.H.N.
Rel
A
Av
N/mm2
B.H.N.
N/mm2
%
Joule
Chemical composition:
340 - 470
140
>
_ 265
>
_ 26
>
_ 27 J ISO-V + 20oC
490 - 630
190
>
_ 345
>
_ 22
>
_ 27 J ISO-V - 20oC
EN 10025, table 3
Processing characteristics:
Welding:
Highly suited; cf. 1.5.8 and 6.1.
Highly suited; cf. 1.5.8 and 6.1.
Warm bending:
Possible at temperatures between

400 and 850oC.

400 and 850oC.
Cold bending:
Possible, but observe DIN 18800,

Part 1.

Part 1.
Additional information about

material; valuable for practical
repairs:
Used only for subordinate welded

components.
Not used in load-bearing
components.
Abt. 95 % of the load-bearing

components are made of this
material.
Filler metals
See page 61
See page 61
2 en - (0)
Page 59
Plate
Plate
Plate
DIN EN 10113-2-S460N(ex.St E460) EN 10037 - S690QL(ex.St E690)
Wear plate 500 HB LV 2 270 002
Fine-grained structural steel
Fine-grained high strength structural

steel
weldable
quenched and tempered
Fine-grained structural steel high

strength
weldable
Normalized or in an equivalent state

induced by normalizing rolling
quenched and tempered in fluid
550 - 720
210
460
17
>
_ 40 J ISO-V - 20oC
790 - 940
~ 300
>
_ 690
>
_ 16
>
_ 27 J ISO-V - 40oC
1550
~ 450 - 540
>
_ 1300
>
_8
>
_ 20 J ISO-V - 10oC
See DIN EN 10113-2
See EN 10037
See manufacturers instructions
Weldable; see 1.5.8 and 6.1
Readily weldable; see 1.5.8 and 6.1

400 and 850C
Part 1
Not possible without postweld

quenching and tempering
Possible by rolling
Weldable as wear protection;

preheating to + 100C
Not possible
Used mainly for hubs on equipment

for construction machinery
Used by O&K for wear-prone parts,

e.g. excavating tools, blades,
wearing edges
Wearing plates welded onto

excavating tools
See page 61
See page 61
See page 61
weldable
normalized
60
Possible with very large radius by

rolling (plate thickness)
2 en - (0)
Materials for welded components

in O&K construction machinery
and mining equipment
Standard designation:
Cast steel
SEW 685 - GS-21Mn5V(ex. GS-52.3V)
Trade name:
Delivery specification:
LV 2 102 375
Cast steel
DIN 17205 - GS - 25 CrMo4V II

SEW 520 - GS - 18 NiMoCr36V
SEW 520 - GS - 22 NiMoCr56V
ESCO - cast steel
Description of material
Cast steel
weldable
Cast steel
Heat treatment state:
Mechanical and technological

properties (reference values):
Tensile strength
Hardness
Yield strength
Elongation
Impact energy
Rm
B.H.N.
Rel
A
Av
N/mm2
B.H.N.
N/mm2
%
Joule
Chemical composition:
480 - 620
~ 180
>
_ 340
>
_ 20
>
_ 35 J ISO-V - 50oC
SEW sheet and O&K instructions
850 - 1000
~ 300
>
_ 750
>
_ 10
>
_ 27 J ISO-V - 20oC
See manufacturers instructions
Processing characteristics:
Welding:
Readily weldable. See 1.5.8 and 6.1 Readily weldable. See 1.5.8, 1.5.9
and 6.1
Warm bending:
Cold bending:
Additional information about
material; valuable for practical
repairs:
Together with plate St 52-3 in

plate/cast steel composite
constructions
Adapters, corner blades; almost all

cast wearing parts
Filler metals
See page 61
See page 61.
2 en - (0)
Page 61

5.2
Filler metals for O&K welded components depending on partner materials and welding
techniques
Part nos. for filler metals are listed in the appendix.
Material 1
Designations
Standard
Delivery instruction
Material 2
Designations, standards
and delivery instructions
as for Material 1
Gas-shielded welding
EN 24063: 135
Standard designations
Trade names
Arc welding
EN 24063: 111
Standard designations
S235JRG2
DIN EN 10025
S235JRG2
S355J2G3
GS-21Mn5V
S460N
EN 440: G 38 4 M G3Si1
AWS A5.18: E 70S-6
EN 439: M21 (shielding gas)
(ex. DIN 8559: SG2)
EN 499: E 38 2 RA 22
AWS A 5.1: E 6013
S355J2G3
DIN EN 10025 oder
LV 2 293 157
(ex. St52-3)
S355J2G3
GS-21Mn5V
S460N
S690QL
GS-25CrMo4V II
GS-22NiMoCr56V
GS-18NiMoCr36V
ESCO cast steel, blade
Wear plate 500 HB
EN 440: G42 4 M G4Si1

AWS A5.18: E 70S-6
EN 439: M 21
(ex. DIN 8559: SG3)
EN 499: E 38 4 B 42
AWS A 5.1: E 7018
(ex. DIN 1913: E 5154 B 10)
S460N
DIN EN 10113 Part 2
(ex. StE460)
S460N
S690QL
GS-25CrMo4V II
GS-22NiMoCr56V
GS-18NiMoCr36V
Wear plate 500 HB
DIN 8575: SG CrMo1

AWS A5.28: ER 80S-G
EN 439: M21
DIN 8575: ECrMo1 B 20

AWS A 5.5: E 8018-C1
S690QL
DIN EN 10037
(ex. StE690)
S690QL
GS-25CrMo4V II
GS-22NiMoCr56V
GS-18NiMoCr36V
Wear plate 500 HB
EN: not standardized

Trade names:
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
EN 757: E 69 5 Mn2NiCrMo B 42
AWS A 5.5: E 110-18M
GS-21Mn5V
SEW 685 and
LV 2 102 375
(ex. GS-52.3V)
GS-21Mn5V
S355J2G3
S460N
S690QL
EN 440: G 42 4 M G4Si1
AWS A 5.18: E 70S-6
EN 439: M21
(ex. DIN 8559: SG3)
EN 499: E 38 4 B 42
AWS A 5.1: E 7018
(ex. DIN 1913: E 5154 B10)
GS-25CrMo4V II
and modifications
DIN 17205 and
LV 262 480
GS-25CrMo4V II

Trade names:
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
AWS A 5.5: E 110-18 M
GS-22NiMoCr56V
and modifications
SEW 520
GS-22NiMoCr56V

Trade names:
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
AWS A 5.5: E 110-18 M
GS-18NiMoCr36V
SEW 520
GS-18NiMoCr36V

Trade names:
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
AWS A 5.5: E 110-18 M
ESCO cast steel

Adapter
S690QL
EN 440: G 42 4 M G4Si1
AWS A 5.18: E 70S-6
EN 439: M21
(ex. DIN 8559: SG3)
EN 499: E 38 4 B 42
AWS A 5.1: E 7018
(ex. DIN 1913: E 5154 B10)
ESCO cast steel

Corner blade
S690QL

Trade names:
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
AWS A 5.5: E 110-18 M
(ex. St37-2)
62
(ex. DIN 1913: E 4332 AR7)
2 en - (0)

Examples of the meaning of designations of filler metals for welding:
Rod electrode
EN 499 : E 38 4 B 4 2
Design. of welding pos.; here: all positions except vertical-down weld
Code no. for type of current; here: direct current
Code letter for coating; here: basic
Code no. for minimum impact energy; here: >
_ 47 joules at - 40C (100F)
Code no. for minimum yield strength; here: Rel = >
_ 380 N/mm2
Code letter for welding technique; here: arc welding, 111
Number of European Standard
European Standard
Former designation: DIN 1913: E 5154 B 10
Welding wire
EN 440 : G 42 4 M G4Si1
Code no. for chemical composition of weld metal
Code letter for inert gas; here: mixed gas EN 439: M 21
Code no. for minimum impact energy; here: >
_ 47 joules at - 40C (100F)
Code no. for minimum yield strength; here: Rel = >
_ 420 N/mm2
Code letter for welding technique; here: metal-inert-gas (MIG) method, 135
Number of European Standard
European Standard
Former designation: DIN 8559: SG 3
2 en - (0)
Page 63
HEAT TREATMENT OF MATERIALS

6.
Heat treatment of materials
The repair of steel components often requires the

use of heat. The instructions on the input of heat with
regard to the materials and working methods used
are to be observed.
6.1
Preheating for tacking, welding, gouging

and flame-cutting
Preheating for tacking, welding, joining and flamecutting is necessary for two main reasons:
It prevents heat from dissipating too fast from the

heat-affected zone. The prolonged cooling time
achieved prevents the formation of hard and brittle
structural states.
Moisture is dried out in the welding area. The

penetration of detrimental hydrogen and oxygen
via the arc into the liquid weld pool is avoided.
Influence of wall thickness and of weld joint
When preheating components for welding, the quantity of heat to be applied depends on the dimensions
of the component and on the weld joint.
T-joint (Fig. 1)
Heat dissipation three-dimensional.
Very rapid heat dissipation due to large component
cross-sections.
Fig. 2
Butt joint (Fig. 3)

Heat dissipation two-dimensional.
Rapid heat dissipation due to large component crosssections.
Fig. 3
Fig. 1
Butt joint (Fig. 4)

Heat dissipation two-dimensional.
Gradual heat dissipation due to small component
cross-sections.
T-joint (Fig. 2)
Heat dissipation three-dimensional.
Gradual heat dissipation due to small component
cross-sections.
Fig. 4
64
2 en - (0)
Prevention of hardness peaks

The formation of structural states which are undesirable due to being too hard and brittle is avoided by
preheating.
The preheating temperature depends primarily on the

material, the shape and thickness of the component,
the welding technique and the climatic influences.
During repair work, it is absolutely essential to observe the temperatures specified in the following list.
In cases of doubt, the company carrying out the
welding must consult a specialized welding engineer
from the relevant O&K plant via the O&K After-Sales
Service about necessary preheating temperatures to
ensure that the repair work is properly done.
Fig. 5
Hardness, non-admissible*
Hardness, admissible*
Hardness in base material, heat-affected, without

preheating
Hardness in base material, heat-affected, with

preheating
Weld metal
Base material, not affected by heat
7 Hardness series
HV Hardness
*
depending on material
2 en - (0)
Page 65

Preheating and interpass temperatures; heating-up and cooling-down rates when repairing by welding
Non-alloyed structural steels in normalized state as per DIN EN 10025 or LV 2 293 157, such as
S355J2G3 (ex. St52-3) and S235JRG2 (ex. St37-2).
Max. heating-up rate, reference value

Min. preheating temperature for tacking and welding:
Wall thicknesses < 25 mm
Exceptions:
- Component temperature below +20C
- Ambient temperature below +10C
- Component wet, moist or dewy
Wall thicknesses >
_ 25 mm
Max. interpass temperature during welding:
All wall thicknesses
Min. preheating temperature for flame-cutting and gouging:
Wall thicknesses >
_ 80 mm
Max. cooling-down rate, reference value:
+ 20C
(70F)
+ 100C
+ 100C
+ 100C
+ 100C
(210F)
(210F)
(210F)
(210F)
+ 250C
(480F)
+ 100C
(210F)
+ 50C/h
(120F/h)
+ 50C/h
(120F/h)
+ 20C
+ 100C
(70F)
(210F)
+ 250C
(480F)
+ 100C
(210F)
+ 50C/h
(120F/h)
High-strength fine-grain steels quenched and tempered in fluid as per SEW 090, part 1, such as
S690Q and S690QL (ex. StE690).

Wall thicknesses >
_ 80 mm
Wall thicknesses >
_ 80 mm
66
(120F/h)
Hot-rolled products made of weldable fine-grain structural steels as per DIN EN 10113, part 2, such
as S460N (ex. StE460).

Wall thicknesses >
_ 25 mm
Wall thicknesses >
_ 80 mm
+ 50C/h
+ 30C/h
(90F/h)
+ 100C
+ 150C
(210F)
(300F)
+ 220C
(430F)
+ 100C
(210F)
+ 30C/h
(90F/h)
2 en - (0)
Wear plates 500 HB as per O&K delivery instruction 2 270 002, such as HARDOX 500, DILLIDUR
500V, XAR 500.

Wall thicknesses >
_ 20 mm
+ 30C/h
(90F/h)
+ 100C
+ 150C
(210F)
(300F)
+ 220C
(430F)
+ 100C
(210F)
+ 30C/h
(90F/h)
Steel castings with a high impact strength at low temperature, quenched and tempered, with good
weldability as per SEW 685 and LV 2 102 375, such as GS-21Mn5V (ex. GS-52.3V).

Wall thicknesses >
_ 80 mm
+ 30C/h
(90F/h)
+ 100C
(210F)
+ 250C
(480F)
+ 100C
(210F)
+ 30C/h
(90F/h)
Heat treated steel casting for castings as per DIN 17205 and LV 262 480, such as GS-25CrMo4V II
and modifications.
High-strength steel casting with good weldability as per SEW 520 and LV 943 661, such as
GS-22NiMoCr56V and modifications.
ESCO steel castings as per ESCO specifications.

2 en - (0)
+ 30C/h
(90F/h)
+ 150C
(300F)
+ 220C
(430F)
+ 100C
(210F)
+ 30C/h
(90F/h)
Page 67
Preheating procedure:
For preheating purposes, the heat must be applied at
a heating-up rate of 30 to 50C/h (90 to 120F/h).
This can be done by one of the following methods:
Electric heating mats

If the fastening elements for the heating mats
have to be welded to the component, the
welding areas must be locally preheated. After
removal of the fastening elements, the welding
areas must be ground to eliminate any microcracking in the component material.
Gas jets
Gas jets must be applied to the component in
such a way that there is no risk of the component being locally overheated. It may be necessary to protect the component from overheating by using heat buffer plates.
Gas burners
Gas burners must burn with a gentle,
low-oxygen flame. The gas flames must not
contact the component because of the risk of
local overheating. The component must be
protected from overheating by using heat
buffer plates.
In all heating procedures, the component must be

covered with insulant mats to prevent excessive heat
dissipation into the environment.
The cooling-down process after welding must not be
accelerated with compressed air, draughts or water.
The weld area must cool down gradually, depending
on material (see data) at a rate of 30 to 50C/h (90
to 120F/h) to room temperature RT = 20C (70F).
For cooling-down purposes, the components must be
covered with insulant mats.
Important: For technical and economic reasons it is
advisable to carry out repair welding with a duration
covering more than one shift with the necessary
preheating and controlled cooling-down continuously,
i.e. in one working operation (day shift - night shift
etc.) If the welding is done only during the day shift,
for example, careful cooling-down to RT and heatingup to the prescribed preheating temperature must be
assured.
68
Temperature measuring
Measuring points for measuring the preheating temperature and the interpass temperature.
Key:
Tv = preheating temperature
Tz = interpass temperature
t = thickness of component
Preheating temperature
Measuring point:
4 x t measured from the centre of
the weld.
Measuring time:
before tacking and welding.
Interpass temperature
Measuring point:
Measuring time:
30 mm beside the centre of the

weld or 30 mm beside the centre
of the last bead
not less than 2 minutes after arc
welding.
Fig. 6
2 en - (0)

6.2
Hot bending of plates
Under the influence of heat, steel loses the mechanotechnological properties that it possesses in the cold
state. This characteristic can be used for hot bending.
The ideal hot-bending temperature lies between 800
and 850oC (1470 - 1560oF) when the material is in
the state of red heat.
In practical repairs, only normalized plate qualities,
such as S275JRG2, S355J2G3, can be treated by
hot bending.
Quenched and tempered steel plates can only be
treated by cold bending or at temperatures between
400oC (750oF) and 550oC (1020oF).
Quenched and tempered steel plates, such as
S690Q, would be overdrawn at abt. 800oC (1470oF)
and lose their mechano-technological properties. This
would require requenching and retempering which is
hardly practicable in field repairs.
Normalized or quenched and tempered steel plates
must by no means be treated by cold bending in a
temperature range of abt. 100 to 350oC (210 610oF), as in this so-called blue-heat temperature
range the material is brittle and tends to the formation of cracks in the bending area.
6.3
6.4
Stress-relief annealing of steel components
For practical repairs, stress-relief annealing is hardly

ever necessary.
If a component is to be stress-relief annealed after
repair or reinforcing, some fundamental rules are to
be observed.
Details of the process are to be discussed with the
annealing workshop before annealing.
Machined surfaces are to be measured before

and after the annealing process. Distortion due to
annealing is to be reworked.
Machined surfaces are to be protected before

annealing against the formation of scale by applying suitable protective coatings.
For pressure compensation purposes, hollow sections are to be provided with drill holes before
annealing takes place. Hole diameter 4 mm.
Annealing parameters:
-
Annealing temperature for normalized materials 580oC + 20oC (1080 + 70oF)
Annealing temperature for quenched and

tempered materials 30oC (90oF) below tempering temperature. This value can be taken from
the relevant standards or the material certificates.
As a rule, the annealing temperature is 530 to
550 oC (990 - 1020oF).
Heating and cooling should take place at a
rate of around 50oC/h (120oF/h). The furnace
may be at a temperature of 150oC
(300oF)when the component is inserted. It can
be opened after cooling when the temperature
is 150oC (300oF). Final cooling can then take
place in calm air.
Hot straightening of plates
Plates can be straightened in a cold and warm state.

In cold straightening, the deforming forces required
are exerted from the outside by means of tools, such
as presses or rolls.
Hot straightening makes use of the interaction produced by the local input of heat:
Elongation of the material in the warmed-up area,
upsetting of the warm material at the transition to the
cold area, shrinkage of the warmed-up area and
straight stretching by internal stresses.
The holding time at annealing temperature in

the furnace should be 2 min. per mm of wall
thickness, but not less than 1 h.
The material should be warmed up to red heat if

efficient straightening is to be achieved.
Here again the material quality is to be taken into
consideration. Only normalized plates can be bent in
a hot state without the loss of mechano-technological
properties.
In hot bending of quenched and tempered plates,
quality losses in the heated areas must be reckoned
with.
2 en - (0)
Page 69

6.5
Stress-relieving of steel components
As a stress-relief annealing of repaired components

is feasible only in rare cases and as machined surfaces may lose their dimensional accuracy in the
annealing process, it is necessary to take other measures for the reduction of stresses.
6.5.1
Warming of components
One means of reducing high local internal stresses,

which may occur, for example, after build-up welding
or weld seam repairs, consists in stress relieving of
the component area concerned.
The area around presumed stress concentrations
must be heated up to 250 to 300C (480 to 570F).
Electric heating mats, gas jets or gas burners can be
used as sources of heat.
Heating up must be done at a rate of approx. 30C/h
(90F/h).
For simply designed components with a wall thickness of less than approx. 25 mm, a retaining period
of 3 h is sufficient. For more compact components
with wall thicknesses of more than approx. 25 mm, a
retaining period of 5 h is necessary.
Cooling-down must be done at a rate of approx.
30C/h (90F/h).
6.5.2
Peening of weld seams
Shrinkage impediments produced during cooling of

the weld seam may lead to high internal stresses
(tensile stress) and to cracks. Unimpeded shrinking
may produce material deformations (angular shrinkage).
Both these undesired conditions can be remedied by
peening.
6.5.2.1 Method of peening
Peening is performed after completion of a weld pass
which may also consist of several weld beads. Peening of individual beads of a pass is not allowed.
During peening, the temperature of the weld seam
should be below 200oC (390F/h). Except for root and
cover passes, all weld passes are to be peened.
Before peening, all traces of slag and spatter on the
weld seam are to be removed. Inadmissible elevations, notches and pores are to be properly eliminated.
The peening chisel has to be run two to three times
over the same area of the weld seam at a speed of
abt. 100cm/minute. Peening must not produce any
sharp notches, grooves and material overlaps. The
surface of the weld pass is to be uniformly treated by
peening.
The component must be covered with insulant mats

throughout the heating-up process.
The temperature differential in the component, e.g.
between high-volume and compact areas and thinwalled, ribbed areas must not exceed 50C (120F).
70
2 en - (0)

6.5.2.2 Peening tools
Peening is to be carried out by means of compressed-air operated riveting hammers and flat
chisels with suitably shaped cutting edges.
The riveting hammers must be of handy shape and
equipped with a throttle valve to reduce the impact
rate.
The hammers must be equipped with a chisel guide
in the direction of impact.
The edges of chisels should have shapes such as
shown in fig. 7 and be hardened.
Fig. 7
Material
Chisel
Riveting hammers
Yield strength Width of

No. of strokes
of weld
cutting edge
per min.
material
b
N/mm2
mm
450 to 530
23
600 to 700
18
Table 1:
1700 +
_ 10 %
Length
without
tool
Piston Stroke Air con- Pressure

length sumption
mm
mm
mm
l/min.
bar
270
to
325
25
to
30
50
to
100
350
to
550
Impact
force
N
300
Technical data of suitable riveting hammers. The width of chisels depends on the yield strength of
the weld metal.
2 en - (0)
Page 71

6.6
Treatment of filler metals
Filler metals, such as rod electrodes, welding wire

coils, welding powder and welding rods, must be
stored so as to prevent them from deteriorating.
This is only possible in heated rooms at abt. 30C
(90F) and a relative humidity of below 50 %.
The packages must remain closed until the material
is used. Unused filler metals must be repacked and
brought back into the storage room.
Why is this necessary?
Coatings of rod electrodes or welding powders
used for submerged-arc welding are hygroscopic,
i.e. they absorb ambient humidity. Without protection, these materials get moist or even wet. During welding, the hydrogen and oxygen contained
in the water penetrate into the weld metal and
make it brittle.
Rod electrodes from new or already opened packages must be redried and stored in a heated box
until they are used.
Manufacturers of rod electrodes issue instructions for
redrying.
Reference values for electrodes with coating type B:
2h at 350C (660F)
3h at 250C (480F)
4h at 200C (390F)
There is often a failure to take this tiresome but
necessary action.
Assistance is now offered by the manufacturers of
rod electrodes.
The rod electrodes are supplied in site-resistant,
moisture-impermeable special packs.
Redrying and keeping warm are no longer necessary
if the rod electrodes are used within 8 hours (1
working shift) of the pack being opened. Hydrogen
content < 5 ml/100 g weld metal.
One box (package) therefore contains a number of
individual packs suitable for use by one welder. The
rod electrodes are vacuum-packed firmly together in
shrink film.
Single rods must not be movable if the packaging is
intact. Prior to opening the pack, it must have been
brought to the ambient temperature at the application
site.
Rust, a chemical compound of iron and oxygen, introduces unwanted amounts of oxygen into the weld
metal, with the result that the material gets brittle.
Corroded welding wire contaminates the wire guide
tubes. This leads to an earlier wear of these elements.
Corroded welding wires and welding rods therefore
have to be discarded.
6.7
Temperature monitoring
For temperature monitoring during heat treatment

processes, the following equipment is recommended:
Electrical temperature probes:

These are easy to handle and provide an exact
temperature reading on an analog or a digital
display.
Manufacturers of rod electrodes issue instructions for

redrying.
Adherent thermometers:
Thermometers with an analog display, which are
attached with magnets to the component.
Temperature-indicating crayons:
These crayons are used to make a mark on the
component to be heated. When the desired temperature range is reached, the colour of the mark
changes.
In principle, this procedure is very simple.
It requires, however, some experience with the
crayons to perceive the changing of the colour.
Wet rod electrodes must be destroyed. In spite of

redrying they can never again be used for welding.
72
Wet welding wires or welding rods are subject to

corrosion. The copper coating offers only a
temporary protection against corrosion.
2 en - (0)
COLD BENDING OF PLATES

7.
Cold bending of plates
Plates can also be treated by cold bending.

In cold bending, it is important to observe the minimum admissible bend radii in order to avoid cracks at
the edges of the bending areas.
The bend radii can be taken from the relevant standards for the different plate materials.
2 en - (0)
They depend on the thickness of the plate and the

direction of rolling. The minimum bend radii transverse to the direction of rolling are more favourable
than those in the direction of rolling.
The minimum bend radius is also influenced by the
welding suitability in the bending area. Due to grain
coarsening and the ensuing embrittlement of the material during heating after excessive cold bending, the
minimum bend radii in accordance with DIN 18800,
Part 4, must be observed.
Page 73
BUILD-UP WELDING
8.
Build-up welding
The purposes for which build-up welding can be used

are manifold. Build-up welding constitutes an important aid in repair practice.
8.1
The welding sequence depends on the hole diameter

and the possibility of handling the component (figs. 2
and 3).
Addition of missing / worn-out material
The addition of material may be necessary due to

wear, deformation, distortion or handling errors during
machining.
Like any other welding, build-up welding, too, requires proper planning of the welding technique and
meticulous execution of the practical work.
The mechano-technological properties of the weld
metal are to be adapted to the requirements of the
base metal.
8.1.1
Build-up welding in drill holes
Before carrying out build-up welding, the worn-out

drill hole is to be enlarged by approximately 4 mm (2
mm cutting depth) either on a horizontal boring machine or by manual grinding.
This is necessary if the new surface of the drill hole
is to coincide after build-up welding and machining
with the homogeneous weld metal deposit and not
with the relatively hard heat-affected zone.
The build-up weld must have a sufficient thickness so
as to obtain a "clean" drill hole surface.
Fig. 2
Fig. 3
For smaller diameters it is common practice to weld

the beads parallel to the holes longitudinal axis. In
large holes, the weld metal can be deposited as a
continuous, spiral-welded bead.
Fig. 1
The individual working steps are shown in fig. 1:

1
worn-out hole
hole enlarged by drilling
steel rings tacked to component as run-off tabs
build-up weld
run-off tabs removed and hole machined to finished size
74
2 en - (0)
BUILD-UP WELDING
Fig. 4 demonstrates the recommended welding sequence by means of a practical example. Hole (B) of
a shovel stick is to receive a new surface by build-up
welding. After welding the lower half of the hole, the
stick is turned over.
8.1.2
Build-up welding on worn-out threads

(fig. 5)
Fig. 5
Fig. 4
2 en - (0)
Before carrying out build-up welding, the worn-out

damaged thread must be cut away on a lathe. The
diameter of the shank is to be abt. 4 mm less than
the core diameter.
Run-out grooves are to be provided in order to ensure that the new contours are located in the homogeneous area of the weld metal.
The shank has to be prolonged with a backing strip
on which the individual weld beads are to end.
If possible, build-up welding is to be performed on a
device with which the component can be rotated.
The shank can be produced by machining.
Page 75
BUILD-UP WELDING
8.2
Correcting of component shapes to improve the flow of forces
Shape-induced notches detected in steel components

can be removed by build-up welding.
8.3
Build-up welding as a protection against

wear
Component surfaces subject to heavy wear can be

protected by welding on wear-resistant materials. For
details see chapter 9 "Wear protection".
This requires particularly careful work in order not to

produce even more detrimental metallurgical notches
removing the shape-induced notches.
Example:
Taper between thick and thin plate in the edge zones
of the component (fig. 6).
Fig. 6
The surfaces must be ground absolutely smooth and

clean, and all grinding drag lines must run parallel to
the lines of force.
76
2 en - (0)
WEAR PROTECTION
9.
Wear protection (hard-facing )
9.2
9.1
Fundamentals
Wear-prone areas are protected by the application of

a wear-resistant weld overlay.
Component surfaces subject to strong wear can be

given a protection by welding wear-resistant material
onto these surfaces.
The need to provide wear-protection should be
known before the machine is put into operation.
If the component is to be hard-faced after putting into
operation, the wear-protection must be applied in
time, i.e. before the base material itself begins to
show signs of wear. A component with worn loadbearing elements can no longer be protected properly
against wear.
The wear protection is not durable, but is also subject
to wear and tear. Due to the particular metallurgical
properties of the hard-facing materials, the rate of
wear is, however, considerably reduced.
The wear protection system must be regularly inspected and carefully maintained.
It is therefore advisable to provide for regular reworking during machine standstill periods or for a timely
replacement of worn-out components.
Reworking of used components can then be performed in a workshop where more time is available.
Build-up welding of wear protection layers
Depending on the conditions of use, the choice is

between a weld metal of high toughness and good
impact resistance on the one hand and greater surface hardness on the other.
Another important factor to be considered for reworking is the materials suitability for being welded out of
position.
An excellent weld metal for this purpose is one containing chromium, tungsten and niobium carbides embedded in a tough matrix and offering at the same
time good resistance to abrasive wear and sufficient
resistance to impact.
Such weld metal has a cumulative hardness of abt.
59 to 61 HRC. For higher values of impact strength,
it is advisable to choose another weld metal with a
lower hardness of abt. 54 to 56 HRC.
The hard and not very tough weld metal tends to
form hairline cracks on its surface which are produced by surface stresses (fig. 1).
An attentive and well-trained repair staff can contribute considerably towards achieving high machine
availability.
In the following chapters several wear protection systems are discussed. The question of which system is
to be applied can be answered only by taking the
specific conditions of use into account. A good decision can be taken only by weighing up and evaluating the advantages and disadvantages of the systems.
Fig. 1
In order to prevent the cracks from running through

into the base material, a so-called buffer layer must
be provided for in case of components subject to
alternating or pulsating loads.
Areas subject to particularly high stresses, such as
the side cutting edges of excavating tools, should
even be protected by 2 buffer layers (fig. 2).
2 en - (0)
Page 77
WEAR PROTECTION
As to the arrangement of the welding spots, it is
important to take account of the direction of flow of
the medium causing the wear (fig. 5).
Fig. 2
The hard-facing build-up weld must always lie exactly

on the buffer layer in order to avoid the risk of cracks
in the base metal (fig. 2).
Fig. 5
Incorrect placing of the spots may lead to scoring

between the rows of spots.
Criss-cross pattern. The criss-cross pattern is to be
applied on smaller surfaces subject to high wear.
On a criss-cross pattern, soft loading material can be
deposited in the intermediate spaces and thus provide an extra wear protection for the base metal
(fig. 6).
Fig. 3
9.2.1
Build-up welding patterns
Spot pattern. The spot pattern is suitable for large

areas which are subject to a relatively low risk of
wear (fig. 4).
Fig. 6
Fig. 4
78
2 en - (0)
WEAR PROTECTION
Full-face build-up welding
Relatively small areas subject to heavy wear are
hard-faced by a full-face build-up weld.
This ensures full-face protection of the base material
(fig. 7).
9.3.2
For hard-facing layers
Only for gravity position welding, e.g. original

hard-facing in the workshop:
Wire electrodes:
DIN 8555 : MF 10 - GF - 60 - RT
filler wire 2 mm
O&K SN 970 133
Reference analysis:
C
Cr
Nb
Si
Mn
5.0
22.0
7.0
0.5
0.7
Rod electrode
DIN 8555 : E 10 - UM - 60 GRZ
5 mm x 450 mm
O&K SN 583 471
Reference analysis:
Fig. 7
9.2.2
Special hints
Before carrying out build-up welding, the base

materials are to be preheated depending on their
material properties.
During welding, the interpass temperature is to be
kept below 250oC (480oF).
Build-up welding should be used only for the protection of base materials with a hardness not
exceeding a B.H.N. of abt. 300.
Due to the welding heat introduced, build-up welding on base materials of greater hardness causes
microstructural transformations in zones of the
material close to the surface, with the result that
hardness diminishes considerably.
Another consequence is the formation of high internal

stresses in the base material.
Only tough base materials can deal with these internal stresses, such as materials with a max. B.H.N. of
300 .
9.3
Filler metals
9.3.1
For buffer layers
Rod electrodes:
EN 499: E 38 2 RA 22
AWS 5.1: E 6013
Cr
Nb
Mo
5.0
22.0
8.0
1.5
8.0
2.5
For out-of-position welding, e.g. subsequent hardfacing in the field:

Rod electrode:
DIN 8555 - E 6 - UM - 60 P
basic-type coating
alloyed core wire
O&K SN 1 939 533
Trade name: EA 600 Kb : VALCO Dusseldorf
Reference analysis:
C
Cr
Si
Mn
0.5
6.0
1.3
1.3
Key:
R
Z
P
UM
MF
GF
T
G
=
=
=
=
=
=
=
=
rust-proof
heat-resistant
impact-resistant
coated
metal-arc welding with filler wire
flux-filled
high-temperature resistant
abrasion-resistant
Wire electrodes:
EN 440: G 3 Si 1
AWS 5.18: ER 70 S-6
2 en - (0)
Page 79
WEAR PROTECTION
9.4
Repair of build-up welds
State of wear 2 (fig. 9)
Worn-out build-up welds must be repaired by rewelding, if required.

Rewelding should be performed as long as remaining
parts of the buffer layer are still visible.
Before rewelding, a surface crack test has to be
carried out.
It is absolutely essential to gouge out any cracks in
the base metal or the buffer layer before welding is
performed. Cracks should never be overwelded!
9.4.1
State of wear
Fig. 9
The repair measures to be taken depend on the

materials state of wear.
The hard-facing layer is completely worn out.
The buffer layer is almost worn out.
Repair measure: Weld 1 new buffer layer and 2 new

hard-facing layers.
Fig. 8
The hard-facing layer is almost worn out.
The buffer layer is still fully intact.

Fig. 10
Repair measure: Weld 2 new hard-facing layers.
Hard-facing and buffer layers have been completely abraded down to the base metal.
Repair measure: Weld 1 new buffer layer and 2 new

hard-facing layers.
80
2 en - (0)
WEAR PROTECTION
9.4.2
Identification of buffer and hard-facing layers
The following are hints to identify the individual layers

of build-up welds:
The existence of remaining parts of the hard-facing
can be identified by grinding (fig. 12).
Fig. 11
Hard-facing and buffer layers are partly worn out

or broken off.
Repair measure: The remainders of hard-facing have

to be removed by ARC-AIR gouging (cf. page 23).
Fig. 12
Never knock off remaining parts of the hard-facing layer. Flying fragments may cause injury!
The sparks produced by grinding a hard-facing layer

are dark red. They fly away in a linear path and
almost without branching.
The gouged-out area is to be ground smooth and

clean before welding 1 new buffer layer and 2 new
hard-facing layers onto the base metal.
A buffer layer consisting of an austenitic, i.e. corrosion-resistant, weld material can be recognized by
the bright colour of the grinding sparks.
If the buffer layer consists of a ferritic weld metal, the
grinding sparks are light red. They branch out and
spatter (fig. 13).
Fig. 13
2 en - (0)
Page 81
WEAR PROTECTION
9.5
Repair of cracks in build-up welds
Damage configuration: The crack in the component

lies in the area of the build-up weld (fig. 14).
Gouge out the crack in the base metal properly and

in accordance with standard practice (cf. page 23)
and weld (fig. 16).
Fig. 16
Fig. 14
Crack
Hard-facing
Base metal
Cracked zone
Run-off tab
Restore the cover over the repair zone by welding

the buffer and hard-facing layers (fig. 17).
First, remove the hard-facing in the cracked area

completely (fig. 15).
The hard-facing layer can be removed only by the
ARC-AIR procedure.
Fig. 17
Fig. 15
82
2 en - (0)
WEAR PROTECTION
9.6
Welding on wear-resistant steel plates or

steel strips
For welding onto curved surfaces with very great

radii, the strips should be abt. 100 x 400 mm and
equally arranged in a staggered pattern (fig. 19).
Wear-resistant plates or strips with Brinell hardness

numbers of up to 500C an be welded onto the
surfaces to be protected.
9.6.1
Arrangement of plates/strips
For welding onto plane surfaces, the wear plates

should have a size of abt. 200 x 300 mm and be
arranged in a staggered pattern (fig. 18).
Fig. 19
The strips must not be deformed. The gap caused by

the curvature of the underlying metal should, if possible, be the same on both sides (fig. 20).
Fig. 18
The plates must be in perfect contact (i.e. without

any gap, if possible) with the surfaces to be protected.
If the plates are greater than recommended and if
their contact with the surface is insufficient, they are
susceptible to cracking or fracturing under compressive or impact loads.
Fig. 20
The stresses produced by pressing the plates against

the surface may lead to the formation of cracks in the
weld seams.
Observation of the recommended plate size moreover
allows partially worn-out areas to be repaired more
easily.
2 en - (0)
The spacing between the plates or strips should not

be too large (fig. 21), so that loading material can fill
the spaces between the plates, thus protecting the
weld seams against wear.
Page 83
WEAR PROTECTION
For a spacing of the plates as a function of the plate
thickness see fig. 21.
Fig. 21
= 10 mm
15 mm
20 mm
a =
6 mm
8 mm
10 mm
b = 20 mm
25 mm
30 mm
The welds in the flow direction of the medium wear

substantially faster than welds positioned transverse
to them (fig. 22).
Fig. 23
The side blades of bucket front sections and backhoes can be protectd with wear strips.
These strips must be made in one piece. They must
end in an area with low working stresses (Fig. 24).
Fig. 22
Narrow areas, e.g. at side walls (arrow, figs. 22 and

23) of bucket fronts and backhoes should therefore
be fitted with interrupted strips.
Transverse joins or slots are filled in with the

medium, forming a self-protection for the welds.
The slipping of the medium is interrupted by the

joins or slots. The medium rolls, reducing the
wear.
Circular weld openings should be avoided, as experience shows that the opening fail to fill in.
Large parts of the weld and of the plate metal are
subject to wear.
84
Fig. 24
Make long, tapering build-up welding at the ends of

the wear strip.
Grind transitions from weld metal to base material
notch-free.
2 en - (0)
WEAR PROTECTION
The welds in longitudinal direction of the strips must

be protected in their layout. Possible layouts:
1.
3.
The welds are severely susceptible to wear. The

layout is not recommended (fig. 25).
The welds are optimally protected.

The layout of the wear strips is recommended
(fig. 27).
Fig. 27
Fig. 25
2.
The welds are susceptible to wear as the excavating device moves back. The cutting edge is
substantially widened. The penetration resistance
is increased (fig. 26).
4.
This layout is recommended only if the side walls

are also fitted with wear plates.
The welds are then protected from wear (fig. 28).
Fig. 28
Fig. 26
2 en - (0)
Page 85
WEAR PROTECTION
The gaps between the plates of the 1st row must be

closed by build-up welding.
If this is not done, the wear plates in the 2nd row
behind the gaps may close (become joined up).
The welds for fixing the plates and strips consist of

soft weld metal which is not resistant to wear. This is
necessary due to the types of material used in the
base body and the wear plates.
Welds positioned in flow direction in particular should
therefore be given a "hard" cover to protect them
from excessively rapid wear.
Fig. 29
Explanations of fig. 29:

1
Direction of flow of medium
Fillet welds
Hard-faced deposit
Fig. 30
Explanations of fig. 30:
86
Metal plate, base material, e.g. S690Q
Wear plate, hardness: ca. 500 HB
Wear plate, hard layer on soft carrier material
Weld metal, soft
Weld metal, soft, buffer pass
Weld metal, hard, hard-faced deposit
2 en - (0)
WEAR PROTECTION
9.6.2
Bending of strips
Strips of a material with a B.H.N. of max. 400 can be

worked by cold bending and adapted to curved surfaces (fig. 31).
Fig. 31
However, bending must be done on a bending roll

and not on an edging press.
Due to bending radii and spring action, bending by
gradual edging would lead to cracks on the side of
the wear plate subject to tension.
Worn-out plates and strips must always be replaced
in time.
Remaining pieces of the wear plate may not be
removed by wedging (fig. 32), unless a notch is
ground into the weld seam in order to create a
predetermined breaking point.
The cutting areas must be ground smooth and clean
and be free from cracks.
9.6.3
Working instructions
Plates with Brinell hardness numbers exceeding

300 must not be treated by hot bending or hot
straightening.
Plates and strips must not be welded onto highly

stressed component edges.
Plates and strips must be fastened to the base

material with a continuous fillet weld running all
around. Tack-welding is not sufficient.
"Soft" filler metals are used for welding. This applies also to the top pass of the fillet weld.
The base material must be preheated in accordance with the material qualities, at least, however, to abt. 100oC (210oF).
For thicknesses up to 20 mm, the wear plates

must be preheated to at least 100oC (210oF). For
thicknesses of 40 mm, a preheating temperature
of 200oC (300oF) is required.
The interpass temperature during welding must

not exceed 250oC (480oF).
9.6.4
Filler metals
Rod electrodes:
EN 499: E 38 4 B 42
AWS 5.1: E 7018
Wire electrodes:
EN 440: G4 Si 1
AWS 5.18: ER 70S-6
Fig. 32
2 en - (0)
Page 87
WEAR PROTECTION
9.7
Welding of plates or strips with wear-resistant coatings
Plates or strips of S275JRG2/S355J2G3 with a previously welded wear-resistant coating with a hardness
of up to 58 HRC may also be welded onto the
surfaces to be protected.
The plate thickness depends on the size of the excavating tool.
If the recommended plate thicknesses are used, the
spacing between the plates should be 15 mm
(fig. 33).
Fig. 35
9.7.1
The strips must be attached by continuous fillet

welds of a = 6 mm thickness running all around.
"Soft" filler metals are used for welding (cf. 9.6.4).

This applies also to the top pass of the fillet weld.
Strips must not be welded onto highly stressed

component edges.
The base material must be preheated in accordance with the material qualities, at least, however, up to abt. 100oC (210oF).
The strips are normally not preheated.

Exceptions: Component and ambient temperatures are below 20oC (70oF) and the strips are
moist.
With regard to the base metal, the interpass temperature during welding must not exceed 250oC
(480oF).
Worn-out strips must be replaced in time.

Remaining pieces of the strips may not be removed by wedging, unless the weld seams are
notched by grinding in order to create predetermined breaking points. Cf. also fig. 32.
The cutting areas must be ground smooth and

clean and be free from cracks before new strips
are welded on.
The prefabricated strips can be cut with a plasma

torch. If this is not possible, the base material
must be cut by grinding or gouging, and the hard
layer be broken.
Fig. 33
Plate thicknesses: e.g.

A
13
19
25
8
13
19
5
6
6
The plates or strips should be abt. 100 x 400 mm

and arranged in a staggered pattern (fig. 34).
Fig. 34
The strips must not be bent. They can nevertheless

be welded onto curved surfaces with large radii if
their central part rests on the base metal and if the
gap at the long sides of the strips is relatively small
and of equal size on the right and left sides (fig. 35).
88
2 en - (0)
WEAR PROTECTION
9.8
Welding of wear-resistant studs
Studs of wear-resistant materials can be welded onto

the surfaces to be protected.
Studs of different sizes, shapes and hardness are
available from dealers specializing in these articles.
Process desription (fig. 36)
The studs are fastened to the welding device

together with the ceramic weld backing. The ceramic backing ring confines the weld pool and
protects it against external influence.
The arc is ignited by pulling the stud away from

the component surface, whereby parts of the stud
and of the base metal are melted.
The stud is pressed into the liquid weld pool. After

cooling the stud is completely welded to the base
metal.
Welding procedure:
Initial contact capacitor-discharge stud-welding
This type of welding requires high-current power supplies.
Before welding it must be checked whether the

power supply available on site has sufficient capacity for weld finishing.
9.8.1
The studs should be placed as closely together as

possible. The distance between studs is determined by the size of the ceramic backing ring.
Close spacing of the studs ensures that forces
acting on the studs are distributed more evenly to
an as large number of studs as possible, thus
reducing the danger of stud fracturing.
Depending on the material quality, the base metal

must be correspondingly preheated, at least, however, to 100 oC (210oF).
Studs must not be welded onto component edges

or component radii.
For instructions on the procedure as well as on studs

and tools, the user is advised to contact specialist
firms.
Stud welding has proved a successful wear protection procedure worldwide.
Rewelding of single studs broken out of the base
material cannot be recommended.
In most cases, the breaking point in the base metal
cannot be ground as smooth as required.
Fig. 36
2 en - (0)
Page 89
WEAR PROTECTION
9.9
Welding cutting edges onto digging tools

of excavators
Prefabricated cutting edges (1, fig. 37) of highstrength, tempered steel can be welded to the excavating tool (2) as a wear-protection material with
good cutting capability.
To facilitate fastening and welding, the excavating

tool should be placed with its blade in a vertical
position.
For welding, preheat blade cutting-edge and
replacing part to 150oC (300oF).
9.9.2
Welding
metals
sequence
(fig. 39) and
filler
Fig. 37
Fig. 39
9.9.1
Working sequence
The contour of the worn-out cutting segment is to

be cut straight by means of a flame torch. Before
flame-cutting, preheat to 50oC (120oF). Grind
flame-cut edges down to the bare metal.
Weld first the root and 1 interpass from one side using
soft filler metals.
Filler metals (soft) for root and 1st interpass
Make a replacing part with the help of a template.

Material: wear-resistant tempered steel; preshaped, available e.g. from the O&K spare-parts
service.
Rod electrodes
EN 499: E 38 4 B 42
AWS 5.1: E 7018
For cutting out the contour and for chamfering the

weld grooves, preheat the material to 50 o C
(120oF).
Grind the weld groove surfaces smooth down to
the bare metal.
Wire electrodes
EN 440: G4 Si 1
AWS 5.18: ER 70S-6
Grind out the root pass from the other side and weld
2 layers as on the other side.
Attach replacing part (fig. 38).
Finish the remaining weld with filler metals adapted

to the material of the cutting edge (cf. page 90).
Weld stringer beads; interpass welding temperature
max. 250oC (480oF).
Work alternately on both sides in order to avoid
distortion of the replacing part.
Fig. 38
90
2 en - (0)
WEAR PROTECTION
Filler metals (hard) for interpasses and cover
passes
Rod electrodes
AWS 5.5: E 11018 - M
Trade names
Thyssen:
Kjellberg-Esab:
Oerlikon:
SH Ni 2 K 100
OK 75,75
Tenacito 75
Wire electrodes
not yet standardized
Trade names
Thyssen:
Boehler:
Union Ni Mo Cr
Ni Cr Mo 2,5 - IG
The seam ends at the transition to the tooth holders

must be ground smooth and clean (arrows, fig. 40).
Fig. 40
The entire welding area must be allowed to cool down

slowly after completion of the weld. Cover up with
glass wool. Never cool with water or jets of
compressed air.
2 en - (0)
Page 91
REPAIR OF CAST-IRON COMPONENTS

10.
10.1
Repair of cast-iron components by

welding
Spheroidal-graphite cast iron
Basically 2 methods requiring different amounts of

work can be applied. Though requiring the greater
amount of work, hot welding mostly yields the better
results.
10.1.2 Cold welding

Welding is carried out with filler metals of different
compositions to the base metal. If the work is carried
out in a workmanlike manner, the weld metal obtained corresponds to the B-quality level in accordance with the VDG Code of Practice N 60. The
weld differs in its mechano-technological properties
from the unwelded material, although in most cases
the weld fulfils the requirements for a given use.
Such requirements have to be defined for each special case.
10.1.1 Hot welding
Welding recommendations:
Welding is carried out with the filler metal of the

same composition as the base. If the work is carried
out in a workmanlike manner, the weld metal obtained corresponds to the A-quality level in accordance with the VDG Code of Practice N 60. The
mechano-technological properties of the weld deposit
are identical to those of the unwelded material.
Keep the welding current as low as possible, so

that the heat-affected zone remains extremely
narrow.
Preheating temperatures of up to 400oC (750oF)

have a strengthening effect on the welded joint.
The welding areas must be clean down to the

bare metal.
Rod electrodes:
DIN 8573 - Typ E NiFe - 1 - BG 23
AWS 5.15: E NiFe - C1
Electrodes - 3.20 mm
O&K SN 8 432 629
Weld short stringer beads and provide for interpass cooling.
For welding, it is required to preheat the workpiece to

600oC (1100oF). After welding, the component must
be subjected to normalizing at 900oC (1650oF).
Because of this requirement, the procedure can be
virtually excluded for field repairs.
Moreover, the component is subjected to great
amounts of heat, so that the dimensional accuracy of
machined surfaces can no longer be guaranteed.
For repairs requiring this type of welding, it is always
advisable to contact a company specializing in this
field of welding repair, because only these companies
have the necessary equipment for preheating and
normalizing as well as for handling hot components.
92
Normalization after welding is not required.

After grinding, the welded area should be checked for
cracks by means of the dye-penetration test.
Cold welding by inexperienced welders may yield
poor results. It is therefore advisable to contact specialized companies for this work as well.
2 en - (0)

10.2
Flaky-graphite cast iron
Here again, 2 methods requiring different amounts of

work can be applied. Though requiring the greater
amount of work, hot welding mostly yields the better
results.
10.2.1 Hot welding

Welding is carried out with a filler metal of the same
composition as the base metal. If the weld is carried
out in a workmanlike manner, the weld deposit obtained corresponds in its mechano-technological
properties to those of the unwelded material.
For welding, the component must be partly or completely preheated to 650oC (1200oF). As the fluidity of
the weld metal is very high, the welding area as such
must be confined by backing devices.
Because of this requirement, the procedure can be
virtually excluded for field repairs.
Moreover, the component is subjected to great
amounts of heat, so that the dimensional accuracy of
machined surfaces can no longer be guaranteed.
For repairs requiring this type of welding, it is always
advisable to contact a company specializing in this
field of welding repair, because only these companies
have the necessary equipment for preheating and
normalizing as well as for handling hot components.
10.2.2 Cold welding

Welding is carried out with weld filler metals of different compositions to the base metal. If the weld is
carried out in a workmanlike manner, the weld metal
obtained differs in its composition from the base material and possesses other mechano-technological
properties than the latter. A homogeneous welded
joint between base metal and filler material cannot be
expected.
2 en - (0)
Therefore, it is not possible to restore all the components original material properties.
Microstructural changes in the edge zones and high
internal stresses cannot be avoided. Due to inevitably
high structural hardening, microcracking cannot be
excluded.
Welding recommendations:
Keep the welding current as low as possible in

order to keep heat application to a minimum.
The temperature in the workpiece should not exceed 70oC (160oF)in an area directly adjacent to
the weld.
Rod electrodes:
DIN 8573 - type E NiFe
AWS 5.15: E NiFe - C1
Electrodes - 2.5 mm.
O&K SN 8 432 648
Always weld short stringer beads in a staggered

pattern.
In order to reduce shrinkage and thus internal

stresses in the component, the beads should be
slightly extended before cooling by hammering.
Cold welding should only be carried out on flakygraphite cast-iron components if it is absolutely indispensable.
It is advisable to contact specialized companies to
carry out this work.
Alternative recommendation:
For the repair of flaky-graphite cast-iron components
another procedure can be successfully applied, i.e.
the so-called "interlock" method.
Repair by means of the "interlock" method can be
carried out only by special firms.
For details see paragraph 10.2.3.
Page 93

The holes are drilled by means of a template. The
remaining metal between the drill-holes is removed by chipping.
10.2.3 Repair of components with the "interlock"

technique
The repair of cast-iron components by welding is
often not possible if the repaired area is subject to
the action of forces.
So-called "interlocking bars" are then inserted into

these joints (fig. 2).
For this reason, a technique has been developed

where cracks or fractures are repaired by "interlocking". Such repair is carried out by means of mechanical tools only and requires no welding.
This procedure represents nevertheless a useful
complementary technique to welding.
Interlocking can be used to join fragments or, if required, newly made replacing pieces of another material, e.g. of cast steel or plate steel.
Process description:
The component is prepared by drilling rows of

holes on both sides and across the fracture line
(fig. 1).
Fig. 2
These bars are made of a steel material which

can be deformed and solidified by hammering.
The bars are inserted into the joints in layers, with

every single layer being hammered in place. In
the process, the interlocking bars are moulded
exactly to the shape of the joints.
This ensures that also the rear areas contribute to
the load-bearing capability of the bars.
The substitute cross-section, i.e. the number of

bars, can be calculated from the ratio of the material strength values of grey cast-iron and steel.
Fig. 1
94
2 en - (0)
TOUCHING UP OF PAINT COATINGS IN REPAIR AREAS

11.
Touching up paint coatings in repair

areas
All damaged or partly removed coatings of the component must be touched up after completion of the
weld. This applies to areas in which
-
welding has been carried out,
additional reinforcing plates have been fitted or

inserted,
coatings have been damaged by thermal (e.g.

straightening, preheating) or mechanical (e.g. lifting gear) action.
The damaged areas of the component are to be

cleaned by mechanical procedures, such as brushing,
grinding or scraping.
Surface purity: St 3 in acc. with DIN 55 928, Part 4,
supplement 1.
The degree of purity required by this standard can be
achieved only by thorough cleaning.
The repaired area is then to be touched up with 2
coats of paint, a priming and a finishing coat.
The priming coat must ensure that the metal surface
is covered up with a sufficient overlap. In the same
way, the finishing coat has to sufficiently overlap the
priming coat.
2 en - (0)
Page 95
APPENDIX
Comparison
Old designation
New designation
Materials
DIN 17100: St37-2
DIN17100; St52-3
DASt-directive 011: StE690
LV 976752: GS-52.3V
Swedish Steel: HARDOX 500
EN 10025: S275JRG2
EN 10025: S355J2G3
SEW 690 Part 1: S690Q
LV 2102375; GS-21 Mn5V (as per SEW 685)
LV 2270002: wear plate 500HB
Filler metals for welding

DIN 1913: E4332AR7
DIN 1913: E5154B10
DIN 8559: SG2
DIN 8559: SG3
DIN 8529: EY6975Mn2NiCrMoB
96
EN 499: E38 2 RA 22
EN 499: E38 4 B 42
EN 440: G3Si1
EN 440: G4Si1
EN 757: E69 5 Mn2NiCrMoB 42
2 en - (0)
APPENDIX
Part nos. for filler metals
The filler metals listed below can be obtained from the O&K spare-parts service.
For orders, please quote part no., quantity and designation of the filler metal required.
Rod electrodes
Standard designation
Dimensions
(mm)
Part no.
for 1 pack
EN 499:
E 38 2 RA 22
4.0 x 450
5.0 x 350
1 367 155
0 583 352
EN 499;
E 38 4 B 42
2.5 x 250
3.2 x 450
4.0 x 450
5.0 x 450
0 583 320
0 425 080
0 425 081
0 425 079
EN 757:
E 69 5 Mn2NiCrMoB42
3.2 x 350
4.0 x 450
5.0 x 450
2 115 741
2 115 742
0 583 344
DIN 8555-E10-UM-60 GRZ

DIN 8555-E6-UM-60 P
5.0 x 450
3.20 x 450
0 583 471
1 939 533
DIN 8573
E NiFe 1 BG 23
2.5 x 250
3.2 x 350
8 432 648
8 432 629
DIN 8575
E CrMo1B 26
3.2 x 350
4.0 x 350
5.0 x 350
1 009 270
0 583 341
0 583 354
Remarks
2. Rod electrodes, vacuum-packed

Dimensions
(mm)
Part no.
for 1 vacuum pack
EN 499
E 38 4B 42
2.5 x 250
3.2 x 450
4.0 x 450
5.0 x 450
1 465 519
1 465 520
1 465 521
1 465 522
2 en - (0)
Remarks
Page 97
APPENDIX
3. Wire electrodes
DIN 8555-MF 10-GF 60-RT
EN 440: G3 Si 1
EN 440: G4 Si 1
DIN 8575: SGCrMo1
Wire electrode
(not yet standardized)
Dimensions
(mm)
P/N for
15 kg coil
2.0
1.2
1.2
1.2
1.2
0 970 133
0 986 861
0 061 147
0 249 785
8 708 592
Remarks
Fa. Thyssen: Union NiMoCr

oder
Fa. Bohler:
NiMoCr 2.5-IG
4. Carbon electrodes for "ARC-AIR Procedure"

Dimensions
(mm)
Part no.
for 1 pack
Carbon electrode
5.0 x 300
6.0 x 300
8.0 x 300
0 589 076
0 788 314
0 530 884
98
Remarks
2 en - (0)
APPENDIX
Umrechnung von foot (Fu) und inch (Zoll) in Meter
Conversion from foot (Fu) and inch (Zoll) to metric measure
1 in (inch) = 25,4 mm (genau)
1 in (inch) = 25,4 mm (exact)
1 ft (foot) = 12 in = 304,8 mm
Beispiel: 4 ft 2 in = 1,27 m
Example: 4 ft 2 in = 1,27 m
in
+0
+1
+2
+3
+4
+5
+6
+7
+8
+9
+10
+11
ft
0.0254 0.0508 0.0762 0,1016 0,1270 0,1524 0,1778 0, 2032 0,2286 0,2540 0,2794
0,3048 0,3302 0,3556 0,3810 0,4064 0,4318 0,4572 0,4826 0.5080 0.5334 0.5588 0.5842
0,6096 0,6350 0,6604 0,6858 0,7112 0,7366 0,7620 0,7874 0,8128 0,8382 0,8636 0,8890
0,9144 0,9398 0,9652 0,9906 1.0160 1.0414 1.0668 1.0922 1,1176 1,1430 1,1684 1,1938
1,2192 1,2446 1,2700 1,2954 1,3208 1,3462 1,3716 1,3970 1,4224 1,4478 1,4732 1,4986
1.5240 1.5494 1.5748 1,6002 1,6256 1,6510 1,6764 1,7018 1,7272 1,7526 1,7780 1,8034
1,8288 1,8542 1,8796 1,9050 1,9304 1,9558 1,9812 2.0066 2.0320 2.0574 2.0828 2,1082
2,1336 2,1590 2,1844 2,2098 2,2352 2,2606 2,2860 2,3114 2,3368 2,3622 2,3876 2,4130
2,4384 2,4638 2,4892 2.5146 2.5400 2.5654 2.5908 2,6162 2,6416 2,6670 2,6924 2,7178
2,7432 2,7686 2,7940 2,8194 2,8448 2,8702 2,8956 2,9210 2,9464 2,9718 2,9972 3.0226
10
3.0480 3.0734 3.0988 3,1242 3,1496 3,1750 3,2004 3,2258 3,2512 3,2766 3,3020 3,3274
11
3,3528 3,3782 3,4036 3,4290 3,4544 3,4798 3.5052 3.5306 3.5560 3.5814 3,6068 3,6322
12
3,6576 3,6830
3,70
3,7338 3,7592 3,7846 3,8100 3,8354 3,8608 3,8862 3,9116 3,9370
Umrechnung von Langen
- Maen
Conversion for units of length
Lange
Length
in
ft
yd
1 inch (Zoll)
0,0833
0,0278
1 foot (Fu)
12
0,3333
0,00019
1 yard
36
1 statute mile (Landmeile)
63 360
5 280
1 UK nautical mile
(engl. Seemeile)
72 960
1 cm
1m
2 en - (0)
mile
cm
2,54
0,0254
0,00016
30,48
0,3048
0,00057
0,00049
91,44
0,9144
1 760
0,86842
1609,3
6 080
2 026,7
1,15151
1 853,2
0,3937
0,0328
0,0109
39,370
3,2808
1,0936
0,00062
UK
n mile
0,00054
0,01
100
Page 99
APPENDIX
Temperatur - Einheiten und Umrechnungsformeln
Temperature units and conversion formulas
Einheiten
Units
Umrechnung in
Conversion into
Benennung
Nomenclature
Kurzzeichen
Symbol
Kelvin
Celsius
Reaumur
Fahrenheit
(K-273.16o)
4/5 (K-273.16o)
9/5 (K-273.16o)+32o
C+273.16o
4/5 oC
9/5 oC+32o
5/4 oR+273.16o
5/4 oR
9/4 oR+32o
5/9 (oF-32o)+ 273.16o
5/9 (oF-32o)
4/9 (oF -32o)
Beispiel:
Umrechnung von
Example:
Conversion from
R in oC : oC = 4/5 oR
Die Grundeinheit der Temperatur ist Kelvin (K).

The fundamental temperature unit is the Kelvin (K).
Als Formelzeichen wird T verwandt.
The symbol used is the T.
Die ebenfalls benutzte absolute Temperatur degree (Grad) Rankin errechnet sich zu
The likewise used Rankine temperature scale for absolute temperatures is related to K
as follows:
100
Rank = 9/5 K.
2 en - (0)
APPENDIX
Hardness - strength comparisen

Vickershardness
HV
kp/mm2
Brinellhardness
HB
kp/mm2
Tensilestrength
80
85
90
95
100
80
85
90
95
100
270
290
310
320
340
105
110
115
120
125
105
110
115
120
125
130
135
140
145
150
Vickershardness
HV
kp/mm2
Brinellhardness
HB
kp/mm2
Tensilestrength
36.4
42.4
47.4
52.0
56.4
360
370
380
390
400
359
368
376
385
392
1210
1240
1270
1290
1330
37.0
38.0
38.9
39.8
40.7
360
380
390
410
430
60.0
63.4
66.4
69.4
72.0
410
420
430
440
450
400
408
415
423
430
1360
1390
1410
1440
1470
41.5
42.4
43.2
44.0
44.8
130
135
140
145
150
440
460
480
490
500
74.4
76.4
78.4
80.4
82.2
460
470
480
490
500
45.5
46.3
47.0
47.7
48.3
155
160
165
170
175
155
160
165
170
175
520
540
550
570
590
83.8
85.4
86.8
88.2
89.6
510
520
530
540
550
49.0
49.6
50.3
50.9
51.5
180
185
190
195
200
180
185
190
195
200
610
620
640
660
680
90.8
91.8
93.0
94.0
95.0
560
570
580
590
600
52.1
52.7
53.3
53.8
54.5
205
210
215
220
225
205
210
215
220
225
690
710
730
750
760
95.8
96.6
97.6
98.2
99.0
610
620
630
640
650
54.9
55.4
55.9
56.4
56.9
230
235
240
245
250
230
235
240
245
250
770
790
810
830
840
19.2
20.2
21.2
22.1
23.0
660
670
680
690
700
57.4
57.9
58.4
58.9
59.3
255
260
265
270
275
255
260
265
270
275
850
870
880
900
920
23.8
24.6
25.4
26.2
26.9
720
740
760
780
800
60.2
61.1
61.9
62.7
63.5
280
285
290
295
300
280
285
290
295
300
940
960
980
990
1010
27.6
28.3
29.0
29.6
30.3
820
840
860
880
900
64.3
65.0
65.7
66.3
66.9
310
320
330
340
350
310
320
330
340
350
1050
1080
1120
1150
1180
31.5
32.7
33.8
34.9
36.0
920
940
67.5
68.0
2 en - (0)
Rockwellhardness
HRB HRC
N/mm2
Rockwellhardness
HRB HRC
N/mm2
Page 101
NOTES
102
2 en - (0)

Bucyrus Welding Ecommendations

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Bucyrus Welding Ecommendations

Enviado por

Direitos autorais:

Formatos disponíveis

2 114 500 en - (02)

Bucyrus HEX GmbH

Loads on structural elements .............................................................................................................. 2

Types of loading .................................................................................................................................. 2

Material behaviour under different loads .............................................................................................. 4

Mechanical notches .............................................................................................................. 5

Metallurgical notches ............................................................................................................ 6

Shape-induced notches ........................................................................................................ 6

Notch effects ........................................................................................................................ 8

Practical experience ............................................................................................................ 9

Grinding drag lines ............................................................................................................ 10

Grinding tools .................................................................................................................... 10

Run-off tabs ........................................................................................................................ 11

Attaching auxiliary elements .............................................................................................. 12

Ends of ribs ........................................................................................................................ 13

Undisturbed flow of forces .................................................................................................. 13

Ribs and stiffeners .............................................................................................................. 14

Welding technique .............................................................................................................. 15

Welding of "tempering beads" ............................................................................................ 16

Buffering of weld edges ...................................................................................................... 16

Welding sequence .............................................................................................................. 17

Planning of repair and reinforcing work for steel components

Causes of damage ............................................................................................................................ 18

Preparatory measures ........................................................................................................................ 18

Scope of repair work

Scrapping of components .................................................................................................. 19

Temporary repair ................................................................................................................ 19

Permanent repair ................................................................................................................ 21

Precautionary examinations .............................................................................................................. 22

Detection of cracks and other defects

Examination for surface cracks with the dye-penetration test ............................................ 22

Ultrasonic testing ................................................................................................................ 22

O&K standards for testing procedures................................................................................ 22

Repair welding techniques

Gouging out and welding of cracks .................................................................................................... 23

Cracks in hub connections

Cracking along the center of the seam .............................................................................. 25

Sharp, exactly radial crack along the unchamfered edge .................................................. 26

Welding on of a metal cylinder by the back-step technique................................................................ 27

Cracks in box-type sections................................................................................................................ 29

Opening of box-type sections ............................................................................................ 30

Removing parts of a chord plate by flame-cutting .............................................................. 30

Backing strips .................................................................................................................... 33

Recommended groove shapes for manual welding with electrodes

Butt joints ............................................................................................................................ 34

WORKING SEQUENCE FOR WELD SEAMS

Butt welds .......................................................................................................................... 36

Double-V butt weld .......................................................................................... 36

V-butt weld with backing strip .......................................................................... 37

T-joints (fig. 53), accessible from 2 sides ........................................................ 37

Closing of working openings, renewal of component areas

Closing a working opening ................................................................................................ 38

Closing a web-plate opening .............................................................................................. 39

Replacing a chord-plate section ........................................................................................ 42

Salient chord plate ............................................................................................ 42

Recessed chord plate ...................................................................................... 45

Possible causes of damage to chord plates .................................................... 47

Repair of a boom with a salient chord .............................................................. 48

Reinforcing of steel components

Working sequence .............................................................................................................. 27

Shapes of reinforcing plates .............................................................................................. 51

Welding slots ...................................................................................................................... 52

Fitting of reinforcing plates.................................................................................................. 53

Weld seams of T-joints ...................................................................................................... 53

2 en - (0)