FABRICATION GUIDELINES

1.0 CUTTING K-TECK SERIES (WRS)

The hard face side up of  K-TECK series wear plate can be cut with plasma or carbon arc or fine abrasive saw blade methods only, OXY fuel type cutting will not cut the hard surface due to the high chrome content

1.0 Cutting with a Plasma Arc

Typical plasma size is of a minimum 250 amps for up half inch plate thicker plate will need a larger power supply for cutting speed and to be slag free.

1.2 Cutting with a Carbon Arc

DC welding power are recommended for Carbon ARC cutting of at least of 75 volts recommended for half inch material , Cutting the plate from the carbon steel side is recommended at all times grind back all surface to remove carbon slag from the base material.  

1.3 Cutting with an Abrasive Saw

Abrasive saw blade can be uses for cutting through the K-TECK hard face surface, ceramic silicon carbide wheel is recommended.
 

2.0 BENDING K-TECK (WRS)

All of  K-TECK series (WRS) can be formed to most fabricated shapes by press brake or rolling methods, the key is the operator experience and to create multiple bend lines because of the hardness of the surface layer.  
K-TECK minimum recommended bend radius when pressing with the hard face to the inside is of general purpose.

Thickness Minimum Bend Radius Typical 
6/7  (BR) 5 Inches 
6/9   (BR) 5.5 Inches 
8/9 (BR)  8 Inches
10/9 (BR) 12 Inches 
12/11 (BR)  16 Inches 


2.1 Rolling K-TECK (WRS)

 Pyramid or stacked rolls is recommended that the top roll be protected with a mild steel sleeve and does not crush the hard face carbide in the process of forming .

When rolling with the hard facing on the outside, a low carbon steel plate should be used
to sandwich the hard facing before rolling, the same size of the base plate thickness should be used to distribute evenly of loading the roller  for forming. 

2.2 Weld Joins

When rolling with weld joints, the alignment of weld joins to the direction of
Rolling is important to reduce the stress points of the weld joints,
Always feed into the rolls that the weld joins are perpendicular to the rollers (parallel to the
Direction of feed). By not using this method plate can break across the weld joint. 

 

2.3 Pressing K-TECK (WRS)

Hydraulic press brake is used for small diameter pipes, cones and square- to-round transitions. Forming can be done with a male-and-female combination of dies, using a bull nose blade is most typical for pressing, a knife edge blade will result in crushing the carbide.   
Forming is done without preheat typically, or with just enough heat to take the chill out of the plate 0-250 degrees centigrade (300-450 F).  The heat will not have an effect on the hard surface.

Square-to-round transitions are the hardest to form because of the 90-degree corners on the square or
Rectangular ends. General preheat in the areas is needed to get better results. The
Area being formed is usually heated to red-hot: about 500 degrees centigrade (950 F) but entire plates can be pre-heated to 500 degrees centigrade (950 F) or more.

 

3.0 FIXING K-TECK (WRS)

K-TECK is a mild steel backing to the hard facing surface this allows it to be easily attached to other mild steel surfaces include perimeter and plug welds, countersunk bolts and studs.

3.1 Perimeter Welds

The simplest way of getting into service is to weld its carbon steel base to the existing
 Steel Structure. The common welding processes: Shield Metal Arc Welding (SMAW),
Gas Metal Arc welding (GMAW), or Flux Cored Arc Welding (FCAW). The base metal is
Carbon steel, any of the following electrodes can be used: E70 18 for SMAW, E70S-X for GMAW, E70T or E71T for FCAW. For SMAW welding the minimum size power supply should be
A 200 amp AC/DC unit; for GMAW welding, a 250 amp 100% duty cycle, constant voltage machine
Is always recommended.

3.2 Fillet Weld Size

Common ways of welding is with a fillet weld. The most important factor is the size of the fillet weld. General practice 
Should be a minimum of 3 mm between the top of the fillet weld and the hard face. The maximum 
fillet weld size can be calculated using the formula:
Max. Fillet Weld Size = Base Metal Thickness minus 3 mm 
It is important the weld pool will not pick up chrome carbide of the hard face matrix as this will make the weld pool brittle as Carbon from the hard face, making the weld brittle and leading to cracking.

3.3 Sheet Spacing

Recommends spacing of approximately ¾ inch between adjacent sheets for best performance. This allows room maximum fillet weld size. In applications, it is possible to reduce gaps by combining plug welds and butting up sheets.
 

4.0 Plug Welds

For better results a minimum hole size of (1") is suggested every (12"-18") on center’s with the base of the A36 welded to the structure with the rest of the hole filled with a Stoody hard facing material. 

4.1 Stud Welds

Studs can be easily welded to the mild steel base. Studs should be no smaller than (3/8”) the number of studs will required engineering loading calculations. Generally stud spacing of 12 inches is
Recommended. Follow the guide lines of the stud manufacture for best results Torque the stud to manufactures specifications.

 

4.2 Bolts

Another method of attaching on fixed or mobile plant is with bolts remember bolt heads and holes disrupt the flow of alloy surface. Turbulence created around
Bolt holes accelerates wear and reduce the life expectancy of your wear liners.

 

4.0 JOINING K-TECK (WRS)

K-TECK (WRS) can be joined to itself or to other structural steels for fabrication keep in mind that different fabrication techniques are different from standard structural steels.

Welding on the hard face is of wear protection only the backing plate is to be welded to the standard of application. K-TECK is not a structure consult with your local welding dealer for more information  

We recommend using either:

1)  E7018 @90-11OA for SMAW.

2) E7OS-X @ 100-110A for GMAW.

The root pass must not melt through the "land" into the hard-faced layer. This can cause hard facing

Carbon to be picked up by the weld metal, resulting in a weld that is hard and brittle. For the fill

Passes, use 4 mm (1 /8") or 5 mm (3/16") E7018 electrode for SMAW welding, depending upon the plate thickness, or a standard E70S MIG wire for GMAW. Use the manufacturers recommended
Amperage range for the electrode chosen.

4.1 Joining Mild Steel Side

 It is best to leave about a 2mm gap between each of the sheets to assist in welding the alloy
Side. All sheets then need to be dogged down hard against the work table the full length during welding, is important for keeping the plate flat.

4.2 Welding the Alloy Hard Facing Side 

Before welding the alloy side, it is important to note that hard face welds are not structural. They are
Simply a sealing weld for the joins to limit any potential gouging wear. No need to bevel the edges on the hard facing side use the recommended Stoody welding hard facing wire or rod.  
When welding the hard face of polished side, extra care should be taken to protect the polished
Finish its recommend using a spatter template to cover the surface.

4.3 Structural Fabrication

K-TECK (WRS) is designed for use as a wear liner, it can be used structurally in the fabrication of
Chutes, hoppers and bins. The fact that its primary use is not structural with the correct engineering, chutes and bins can be made from K-TECK (WRS) during the design process, however, this section can be used as a preliminary design guide.

 

5.0 POLISHING

Follow the disc 1 and disc 2 procedure for optimum results in fabrication or in service polishing for buckets and liners that are carrying a ‘dead’ load that require a higher level of initial polish to improve material flow. K-TECK SUPERGLIDE is a pre-polished finish to suit your application of service.
A final post-installation polish is necessary to remove any traces of weld spatter from the hard face surface, do not installed rusted surface for a carry back or anti hang up solution

6.0 REPAIRING K-TECK (WRS)

The hard surface can be hard to work with and is easily damaged in Fabrication,
Cracks and chips can be repaired without compromising the wear performance of the liner follow the Stoody Guide for best recommendations of hard face rod selection. 

7.0 THERMAL EXPANSION JOINTS (CRACKS)

There are two main types of non-ferrous hard surfacing alloys – cobalt-based alloys and nickel-based alloys. Both these alloys offer wear resistant properties to combat most of the major types of wear. However, due to their higher cost, they are mainly exclusively used in applications where their unique properties are economically justified.