FLOOD WELDING SERVICES
FLOOD WELDING BY SKILLED WELDING TECHNICIANS
Your Flood Welding Experts
With 50 years of experience, MPD Welding Grand Rapids Inc provides flood welding to Grand Rapids, MI and the Midwest. Flood welding is a type of welding that uses a unique method of depositing vast amounts of weld metal.
Similar to MIG welding and TIG welding, the flood welding process is applied on large die sets and components such as bolster plates, forging dies, hammer rams, die holders and ejector holders.
The Flood Welding Process
The process is accomplished by using up to 5/32” diameter flux cored wire. Both processes can develop weld metal deposits of up to 60 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 1,200 when using wire, and between 1,200 and 1,600 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 Heat Treatment Process
The most important factor in effective flood welding is heat treating. This is a controlled process of heating a material to a target temperature.
The temperature of the block must be carefully maintained throughout the scarfing and welding process. Heating the metal with 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 Grand Rapids 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 technicians in the business.