With over 35 years of experience, MPD Welding-GR, Inc. provides flood welding to Grand Rapids, MI and the Midwest. The term flood welding was coined to describe a unique method of depositing vast amounts of weld metal. The flood welding process is normally applied on large dies and components such as bolster plates, hammer rams, die holders and ejector holders.
The process is accomplished by using either large diameter coated welding electrodes (3/4” diameter x 36” long) or up to 5/32” diameter flux cored wire. Both processes can develop weld metal deposits of up to sixty pounds per hour. Flood welding is used to fill the cavities that are left after scarfing cut cracks and/or fatigued work surfaces. The carbon arc or high pressure oxyacetylene processes are employed for scarfing.
Once all of the cracks and worn surface areas are removed fully, the section is preheated and positioned to receive the weld metal. The welding is usually done in the semi-vertical position, depending on the depth and position of the cavity. Using either large diameter coated electrodes or high deposition flux core wire, the welding process is started by establishing a liquid metal puddle at the bottom of the cavity. High amperage and voltage is maintained throughout the weld process. The amperage is kept between 800 and 1200 when using wire, and between 1200 and 1600 when using coated electrodes. Voltage ranges between 38 and 42 for both processes.
Once the liquid weld metal puddle is established, the welder simply manipulates the electrode or wire from one side of the cavity to the other while the slag rolls off and freezes, creating a protective shell over the hot weld metal during solidification. The welding process is continuous, stopping occasionally only to peen at the forging temperature (dull red).
The end result is a welded repair that has the mechanical integrity to perform under both extremely high pressure and maximum impact conditions.
The most important factor in effective flood welding is heat treating. The temperature of the block must be carefully maintained throughout the scarfing and welding process. Precise preheat and post-heat procedures must be followed. In order to do the job correctly, the welding facility must be equipped with adequate furnace capacity.
MPD Welding-GR, Inc. has invested in the necessary furnaces, cranes and welding equipment to do any die or component that can go over the road. Our company also has the most experienced flood welding people in the business.
Contact MPD Welding-GR, Inc. today at 616-248-9353 for all of your Grand Rapids, MI
welding services needs.
