Issue 10.
05
Cost Effective for a Variety of Applications:
KALMETALL-W Hard Overlay Welding
Various components that have been provided
with KALMETALL-W hard overlay welding
KALMETALL-W incorporates
several hard overlay welded steel
systems that consist of a tough
basic body and hard overlay
welding.
The base metal provides the
strength of the system. Depending
on the specific application, it is
made of standard or special
steels.
www.kalenborn.de
KALMETALL-W
n is characterized by
high abrasion resistance,
high impact strength and/or
high thermal stability
n has a wide range of applica-
tions and can be adapted to the
specific use by varying the alloy
of the hard overlay welding
Welding Service
n individual overlay welding of
various elements and components
n work carried out either at the
customer or at the Kalenborn
premises
n specialist for the regeneration
of grinding system components
Hard Overlay Welded Plates
n steel plates of varying quality,
thickness and dimensions; cost
effective for large surfaces
n custom fabricated components
which are made to the particular
requirements of the customer
n low weight and high economy
The hard overlay welding is the
provided the component is a self-
wear layer. It consists of a C-Cr-
supporting structure
Fe system with primary chromium
carbides. The carbides provide
the extreme hardness of the
overlay welding. Depending on
the composition of the alloy, the
hardness may be up to 820 HV.
 kalpraxis KALMETALL-W
Hard Overlay Welding

Solution to Numerous Wear Problems

Microstructure of Kalenborn welding service: Hard overlay welded

KALMETALL-W 143 regeneration of a grinding roll standard plates

Hard Overlay Welding with The Range of Products The Advantages

Primary Chromium Carbides
The hard overlay welding is the
wear layer. It consists of a C-Cr-
Fe system with primary chromium
carbides.
Different types of hard overlay
welding are offered. The particular
alloy is chosen with due regard to
the following criteria: abrasive
stress, impact load and tempera-
ture load.
Technical Data (Reference Values)
Offered by Kalenborn
n complete wear protection
systems depending on the
specific application
n varying alloys of the welding
material
n application of the welding
material as single or multi
layered system
n combinations of ceramic and
metallic solutions to ensure a
component design matched to
the particular abrasive stress
and offering high economy
of KALMETALL-W
n specially fabricated compo-
nents which are made to the
particular requirements of the
customer
n wide range of application and
adaptation to the particular use
n low weight and high economy
provided the component is a
self-supporting structure

KALMETALL Chemical composition Hard- Max. Resistant against

of welding material % ness application
C Cr Mo Nb B Fe HV temp C abrasion impact temp

W 100 5 30 - - - 60 700 350 xx x x

W 143 5 22 - 7 - 60 740 350 xxx x x
W 145 5 21 7 7 - 60 800 750 xxx x xxx
W 150 5 30 - - 1 60 820 350 xxxx - x
W 151 5 30 3 - - 60 700 550 xx x xx

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Kalenborn Welding Service
KALMETALL-W

Rolls, Tables, Pipes, Components

The Kalenborn welding service

offers overlay welded solutions for
most varying applications. These
include, for example: clinker dust
collecting pipes in cement plants,
pulverized coal bends in power
plants, sinter discharge tables in
steel works, etc.
The structures are made of steel
qualities matched to the specific
application and are provided with
an optimized welding alloy.
In addition to fabricating wear Overlay welding of a grinding table with KALMETALL-W
protected structures, Kalenborn
is the approved provider for the
regeneration of worn components.
Typical examples are grinding
rolls and grinding tables made of
chill cast iron for size reduction of
coal, limestone and clinker.
Grinding rolls or grinding tables
are refurbished by the Kalenborn
welding service by means of
automated welding methods.
To avoid the complex dismantling
of grinding tables, regeneration
may also be done with the tables
installed.
Automatic welding machine for inside armoring of a pipe
The grinding table is turned by
means of an auxiliary drive and
the welding procedure proceeds
Technical Data: n minimum diameter of inside
automatically until the final con-
armoring 90 mm (maximum length
tour of the grinding table has Grinding Rolls 1,000 mm)
been restored. and Grinding Tables
n maximum pipe length of inside
The necessary work can either n maximum weight/unit 15 t armoring 5,000 mm (at 250 mm
be carried out at the customer's n maximum height of overlay diameter)
plant or at the Kalenborn welding 60 mm
premises.
Armoring of Pipes
n overlay welding inside
or outside
n minimum wall thickness of
pipes 6 mm

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 kalpraxis Kalenborn Standard Plates
KALMETALL-W

Technical Offer

Standard Plates
Dimensions:
n 1,400 x 2,900 mm
n 1,150 x 2,400 mm
n 900 x 1,900 mm

Base Metal and Overlay

Welding
n base metal thickness from
5 mm upward
n standard thickness of overlay
welding 3 to 12 mm, 18 mm
Standard plates Cutting of standard plates by at a maximum
KALMETALL-W 100 6 + 4 means of plasma arc cutting
Base Metal Qualities
n structural steels
n fine grained structural steels
n high temperature steels
n corrosion and heat resistant
steels
n wear resistant plates

Plate Cutting
Kalenborn offer different cutting
techniques. Plates of most
varying size can be cut.

Joining plate segments to Fabricating complete

structural components KALMETALL-W structures

Kalenborn Attachment Systems

Plug welding Rear welding to the Rear welding to a nut Screw-type fastening by
basic body with internal thread welding a bolt to the
rear side
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Technical Solutions

Hole Punching
KALMETALL-W standard plates
can be provided with the following
holes made by way of plasma arc
cutting:
n square from 12 x12 mm upward
n round from 12 mm diameter
upward
n tears from 5/8 mm diameter Plasma arc cutting is an excellent means for cutting
upward KALMETALL-W plates
n slots from 4.5 mm width upward
When smaller holes are required,
they can be made by water jet
cutting.

Plate Forming
In view of the welding technique
used, KALMETALL-W plates can
also be shaped by cold forming.
The smallest cold rolled diameter
measures 250 mm for inside
armoring and 500 mm for outside
armoring.

Optimal Solutions Cold forming of a KALMETALL-W plate

Kalenborn offer the complete array

of solutions using hard overlay
welded KALMETALL-W.

Joining KALMETALL-W segments to a pipe section

by means of welding

Screw-type fastening Suspended system

by counter sunk rings
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 kalpraxis KALMETALL-W Suitable for
many Branches of Industry

Cement Industry

Typical applications of KALMETALL-W:

n clinker coolers n mill linings

n clinker chutes n raw material chutes
n dust pipes n screw conveyors
n fan lining n separator blades
n fan blades n separator linings
n grinding rolls
n grinding tables

Wear protected housing made of KALMETALL-W for a Separating cones of cement classifiers made of
raw meal fan, 2,000 mm diameter KALMETALL-W 100 6 + 4, 3,000 mm diameter

Plate of a reciprocating clinker grate cooler armored Screw conveyor for transporting clinker; the screw
with KALMETALL-W 145 flights have been armored on both sides with
KALMETALL-W 100, 800 mm diameter
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Fan housing and fan blades for Separator cage for clinker grinding lined with KALMETALL-W 100 6 + 4,
pneumatic systems are reliably cage diameter 3,150 mm
protected with KALMETALL-W

Clinker transport
pipe made of
KALMETALL-W 100,
inside diameter
300 mm

Screw conveyors protected

with KALMETALL-W 100,
up to 2,000 mm diameter,
up to 10,000 mm length

Raw meal transport pipe made of KALMETALL-W 100,

1,500 mm diameter
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 kalpraxis KALMETALL-W Suitable for
many Branches of Industry

Steel Industry

Typical applications of KALMETALL-W:

n belt transfer points n pressure equalizing

pipes
n blast furnace center
pipes n sieves for hot and
cold sinter
n bunkers
n sinter cooler linings
n chutes
n sinter discharge tables
n distributing chutes
n throat armor
n dust collecting pipes
n flumes n vibratory conveyors

n furnace top bells

Pipe armored with KALMETALL-W 100 installed in Pressure equalizing pipe set up near a blast furnace;
a dust collecting system; inside diameter 400 mm, the base metal has a thickness of 30 mm, the thick-
system thickness 8 + 5 ness of KALMETALL-W 100 hard overlay welding
measures 6 mm; 450 mm diameter

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KALMETALL-W 100 pipe for coke transport, Sinter discharge table provided with a combined
inside diameter 500 mm lining made up of KALCOR zirconium corundum
and KALMETALL-W 145

Down pipes of a direct reduction pipeline made of KALMETALL-W 143 lining of a vibratory chute set up
KALMETALL-W 151; the inside diameter measures 355 mm, in a sintering plant; the lined surface covers 10 m
the thickness of the base material 1.4829 is 12.8 mm
Weir step in a
sintering plant
fabricated of
KALMETALL-
W 100 8 + 5
standard plates

Sieves for hot sinter made of KALMETALL-W 145;

the sieve surface is of fishbone design
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 kalpraxis KALMETALL-W Suitable for
many Branches of Industry

Coal Power Plants

Typical application of KALMETALL-W:

n coal bunkers n pulverized coal bends

n coal transfer n pulverized coal

equipment burners

n grinding rolls n pulverized coal

distributors
n grinding tables
n pulverized coal fans
n mill linings
n separator linings
n pipes

Pulverized coal fan housing lined with Pulverized coal burner lined with KALMETALL-W 145
KALMETALL-W 100

Regenerated grinding roll of a coal pulverizer, Pulverized coal pipes for boiler firing made of
1,500 mm diameter KALMETALL-W 100; the guide plates have been
armored on both sides; inside diameter 350 mm
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Further Branches of Industry

Typical applications of KALMETALL-W:

n bunkers n pipe bends

n chutes n pipes
n discharge tables n screws
n fans n separators
n flumes n vibratory conveyors
n mixers

Inside lining of a concrete mixer; the side walls, the bottom and the discharge elements have been protected
by KALMETALL-W 100; 3,500 mm diameter

KALMETALL-W 100 cone with Adapter from round to rectangular shape of a pneumatic transport pipe -
inspection opening integrated in protected by KALMETALL-W 100
a pneumatic transport line
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kalpraxis Optimal Solutions
with KALMETALL-W

Material Combinations

Concrete mixer: KALMETALL-W applied to the side Immersion pipe of a cyclone for separating slag sand
walls and KALOCER high alumina ceramics to the in the cement industry; the pipe inside has been lined
mixer bottom exposed to maximum abrasive wear with KALCRET hard compound; the lid is protected
by KALMETALL-W 100 armoring

Spiral housing of a cyclone sepa-

rator operated by the refractory
industry made of KALMETALL-W
and designed as self-supporting
structure for weight reduction;
the surfaces that are particularly
endangered by abrasion have
been protected by KALOCER high
alumina ceramics

Ask Kalenborn for additional information Kalenborn Kalprotect -

Dr. Mauritz GmbH & Co. KG
KALMETALL-W GB 2 000 WA-GAE/PE 10/05 by Kalenborn 2005

Asbacher Strasse 50
D-53560 Vettelschoss
Germany
Phone +49.(0) 2645.18-0
Fax +49.(0) 2645.18-112
Fax +49.(0) 2645.18-180 (Exp.)
kalenborn@kalenborn.de
www.kalenborn.de

KALENBORN, ABRESIST, KALCOR, KALOCER, KALSICA, KALCRET, KALMETALL, KALINOX and KALEN are trademarks of Kalenborn Kalprotect.
This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reserved.