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REPAIR WELDING PROCEDUREVFE RWP-3 (DUCTILE IRON)

1.0 SCOPE

This procedure covers the repair welding of

pearlitic and ferritic ductile (or nodular) iron. The

corresponding base material specifications are

VIWI MS1 or equivalent.

2.0 DEFECT REMOVAL

The defect may be removed by chipping, grinding

or machining. While carbon-arc may be used on

ductile iron, it is not recommended due to

thermal shock and the formation of

carbide/martensite structure on the surface of

the cavity.

It is important that the weld cavity consist of

sound, clean metal. In critical areas, the use of

magnetic-particle or dye-penetrant inspection is

strongly recommended.

3.0 PREHEAT TEMPERATURE

The preheat temperature is 550° F (290°C).

Preheating should be done in a temperature-

controlled furnace. Begin heating the part at

100° F (40° C), holding one (1) hour/inch (25

minutes/cm) of metal section for six (6) hours

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USER’S GUIDE TO SAFE OPERATION

NOTICE: This guide contains

important information about

the use and characteristics of

the Vulcan Pile Hammers.

Because misuse of this

machinery may result in

injuries to personnel and the

loss of property, this guide

should be carefully reviewed

by all maintenance, operating

and support personnel.

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GUIDE-SAFE-OPERATION/)

HAMMER SPECIFICATIONS

ONSHORE HAMMER

SPECIFICATIONS

(HTTP://WWW.VULCANHAMMER.COM/ONSHORE-

HAMMER-SPECIFICATIONS/)

OFFSHORE HAMMER

SPECIFICATIONS

(HTTP://WWW.VULCANHAMMER.COM/ONSHORE/)

REPAIR WELDING PROCEDURES

Repair welding is an

important part of any

construction site. A wide

variety of repairs can be

maximum. Raise the temperature 100° F (40° C)

per hour to 550° F (290° C), hold one hour/inch

(25 min/cm) or six (6) hours maximum.

Localized preheating may be used when furnaces

are not available. The following precautions

should be observed:

1) The area preheated must be at least two (2)

feet (60cm) from the edge of the weld cavity.

Castings more than 6 inches (15cm) thick should

be preheated at least three (3) feet (90cm) from

the cavity.

2) Heating must be done slowly and evenly.

Temperature gradients of more than 100° F (40°

C) should be avoided.

3) The temperature must be uniform throughout

the section preheated. Holding times of one

hour/in (25 min/cm) of metal section should be

observed.

4.0 INTERPASS TEMPERATURE

The interpass temperature is 700° F (370° C)

maximum. When practical 600° F (320° C)

should be used, but in no case exceed 700° F

(320° C).

5.0 WELDING PARAMETERS

The “shielded metal arc welding” process

(SMAW) should be used for all welding.

A. Welding Current: Direct-current, reverse-polarity

(DCRP) is required for the electrodes recommended. The

voltage and amperage settings should be based on the

recommendations of the electrode manufacturer.

B. Electrodes: Two (2) electrodes are recommended. The

first produces a machinable weld deposit and a lower

hardness in the heat- affected-zone (HAZ). The second

electrode produces a higher strength weld but may be

difficult to machine. Greater care is also required in

welding with the second electrode to prevent cracking in

the fusion zone.

1. AWS ENiFe-CI. This is a 55% nickel electrode having a

weld strength of about 50,000 psi (345 MPa) tensile

strength. It requires a lower amperage and less heat

input. It melts at lower temperature than carbon-steel

electrodes, therefore, creates less carbide-martensite in

the HAZ.

2. AWS E-7018 (E7016 or E7015). This is a carbon steel

electrode with a higher strength as-deposited, 70,000 Psi

made to Vulcan equipment

with welding; however, it

must be done with care and

with procedures that are in

many cases beyond the

capabilities of the ordinary

construction site. The repair

welding procedures we have

online are as follows:

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WELDING-PROCEDURES/)

RAM POINT REPLACEMENT

In order to remove an old

point, the side pins (if any)

will have to be drilled out

before any force is applied to

the Ram Point. A force of 50-

200 U.S. Tons or even

greater may be required

against the flat end of the

neck of the Ram Point inside

of the Ram. If sufficient force

is not obtainable to press

the old point out, closely

spaced (1/4" (6mm) apart)

holes should be drilled in the

neck or the ram point for the

full depth as shown below.

This will immediately reduce

the radial gripping action of

the surface of the neck of

the Ram Point in contact with

the Ram, and thus lessen

the pressure necessary to

dislodge the old Ram Point in

pressing it out.

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FOUNDATION-EQUIPMENT-

REPLACEMENT-RAM-POINT/)

ENGINEERING NEWS & GATESFORMULA TABLE

This page is to enable you to

instantly develop the

capacity/resistance table vs.

blow count for two widely

(485 MPa) maximum tensile. It requires a higher

amperage, more heat input, and is more susceptible to

cracking.

As with all low-hydrogen electrodes, they should

be stored in a warm, dry compartment after the

cans are opened.

6.0 TECHNIQUE

The weld bead should be of stringer type. The

arc should be struck on the weld deposit

whenever possible. The slag should be removed

from the weld deposit between each pass by

chipping, peening and wire brushing.

7.0 POST WELDING HEAT TREATMENT

All ductile iron castings should receive a post-

welding heat treatment. Material poured to

specification VIWI MS1 Grade 1 need only be

stress-relieved while VIWI MS1 Grades 2 and 3

material should be normalized and tempered.

The recommended heat treatments are as

follows:

(A) Grade 1. Place in a furnace at 200° F (95° C)

and soak for one (1) hour per inch (25 min/cm),

six (6) hours maximum. Heat slowly at 100°

F/hour (40° C/hour) to 1100° F (600° C) and hold

one (1) hour per inch (25 min/cm), six (6) hours

maximum. Cool in still air.

(B) Grades 2 and 3. Place in a furnace at 200° F

(95° C) and soak for one (1) hour per inch (25

min/cm), six (6) hours maximum. Heat slowly at

100° F (40° C/hr) to 1000° F (540° C) and

200°F/95° C/hr to 1650° F (900° C); hold one

hour per inch (25 min/cm six (6) hours maximum.

Cool in still air. When the temperature of the

casting is below 600° F (320° C), it may be

placed into a tempering furnace, soaked at 600°

F (320° C) for one hour per inch (25 min/cm) six

hours maximum, and heated slowly 200° F per

hour/95°/hr) to 1200° F (650° C). Hold at

temperature for one (1) hour/inch (25 min/cm)

six (6) hours maximum and cool in still air.

8.0 PRECAUTIONS

The welding of ductile iron presents two (2)

problems:

used dynamic formulae

(Engineering News Formula &

Gates Formula).

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NEWS-GATES-FORMULA-

TABLE/)

VULCAN HAMMER ACCESSORYGUIDE

Vulcan hammers are

designed in "families" of

accessory sizing that are

designed for maximum

adaptability of accessories to

a wide variety of hammers.

Below is a guide to that

interchangeability. While we

can verify the compatibility of

Vulcan and Raymond

accessories, the guide to the

Conmaco accessories is just

a guide and we cannot

accept responsibility for

problems arising from the

mating of our accessories

with their hammers and vice

versa.

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1-FAMILY-HAMMER-

ACCESSORY-GUIDE/)

VULCAN ON-SHORE TIPS

One of the most successful

information programs Vulcan

ever conducted was the

Vulcan Tips program. The

first tip was issued in 1973.

Although most of them were

issued in the 1970's, Vulcan

issued Onshore Tips until the

late 1990's. They went

beyond the Vulcan Data

Manual in providing practical

suggestions for proper

operation of Vulcan

hammers.

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1. The base metal when melted at the fusion zone will not

resolidify as ductile iron — the graphite will precipitate as

vermicular or quasi-nodular. The ductility and impact

resistance will be reduced about 50%, and some carbides

are likely to form, particularly in the pearlitic grade.

2. The HAZ will produce a martensite, especially in the

pearlitic grade, which must be tempered to restore any

ductility. Ductile iron is more susceptible to welding

stresses, and more likely to crack while welding or during

cooling.

Therefore, ductile iron should never be welded in

highly stressed parts or areas. Welds should

never be made when the weld is more than 20%

of the metal thickness.

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HAMMER-SHORE-TIPS/)

VULCAN OFF-SHORE TIPS

The idea of the Vulcan Tips

was to provide practical

maintenance information on

a periodic basis to the end

users of Vulcan equipment. A

great deal of information was

conveyed with the tips; some

of it was later incorporated

into the Vulcan Field Service

Manuals.

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HAMMER-SHORE-TIPS-2/)

WARRANTY POLICY

This warranty policy of Pile Hammer Equipment applies to new products and if specified by Pile

Hammer Equipment, refurbished equipment. Pile Hammer Equipment warrants these products

against defects in workmanship and materials and certifies that these products meet or exceed

factory specifications. Pile Hammer equipment makes no other warranty, express or implied. Our

obligation and liability under this warranty is expressly limited to repairing or replacing, at Pile

Hammer Equipment’s option, any product which fails to meet these specifications within 180 days

from the date of initial use, but not to exceed one year from the date of delivery. This remedy is

exclusive and Pile Hammer Equipment’s obligation doesn’t not include any transportation charges

or costs of installation or any liability from direct, or indirect or consequential damage or delay. If

required by Pile Hammer Equipment, products or parts for which a warranty is made are to be

returned, transportation prepaid to Pile Hammer Equipment. Any improper use, operation beyond

rated capacity as stated in the written specifications, substitution of parts not approved by Pile

Hammer Equipment in writing shall void this warranty.

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