Help to Identify This High Si Casting Alloy

[tc7]

Hi-
I have the task of attempting a weld repair on some lead pots used in a heat treatment plant. The casting is very porous so I don't know if this can even be done. However, I must try. Don't know what the alloy is, but this is the chemistry as shown by a spark test:
Fe 95.28
C 0.113
Si 2.166
Mn 0.944
Cr 0.000
Ni 0.090
Mo 0.083
Cu 0.386
Al 0.211
V 0.018
W 0.752
Ti 0.082
Nb 0.060
S 0.144
P 0.062

Any best guess on the spec for this? Then I would be able to zero in on my weld procedure.

Thanks for any advice.

 

[metengr]

tc7:
Based on your stated chemical analysis results and review of the Supplementary Castings Handbook, the high silicon is more common in higher alloy steel castings or tool steel type castings with higher carbon content.

I don't believe you are going to able to dovetail this cast material into a casting specification.

Can you provide information as to the type of weld repair you are envisioning? Based on this, we might be able to prescribe a filler metal and process.

 

[arunmrao]

How sure are you about the spark test? Perhaps removing a piece and testing on OES might give a more meaningful result. High Si cast irons are normally used for such applications,but your carbon content does not seem to confirm it. What is the size of the pot?
I have been casting pots for various applications, but I have not encountered this chemistry.

I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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[tc7]

Metengr-
The pots have many cracks (see photo). I was envisioning grinding out deep and wide to clean matrial amd then SMAW repair using an Inconel 182 because of it's high Mg content (~6.5%) to offset the high sulfur reading and the Inconel's high nickel content which is good for all around general "maintenance" repairs. Any better choices, assuming the chemistry is reasonably accurate?

Arunmrao-
Our ArcMet tester is pretty accurate on C readings. The Si may even be higher than the 2.166% indicated because the machine gave a flag that it is beyond the calibrated range.

 

[metengr]

tc7:
I agree with your proposed filler metal. Regarding the repair itself, this could be a significant weld repair if the cracks shown exceed 50% of the wall thickness of the lead pot casting, and the casting is poor quality (defects). For preheat requirements I would use 350 deg F for weld repairs.

Have you thought about an RT or even UT to evaluate the soundness of the lead pot casting before attempting weld repair? Just curious.

 

[arunmrao]

Any major welding is normally not advised for safety reasons. The pot can crack and open up while it contains molten salts. Alternately while the pot is being transported,it could just split into two.

Very recently an empty aluminium melting pot was being transported in the foundry. It cracked and fell,fortunately no harm done. I was immediately called as they suspected I had cast the pot. It was not mine ,but sourced elsewhere,(my monogram saved the day).

I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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[tc7]

Met-
After UT'ing the pot throughout, it became clear that the spider web of indications could not be reliably, completely or safely repaired.

As we don't know who the OEM for this equipment was, I wonder if this pot can be used as a mold to cast a duplicate?

Arunmrao- what material specs would be appropriate for a lead pot? and who in the industry may provide duplicate equipment?

Thanks

 

[metengr]

tc7;
I would recommend you get in contact with arunmrao. His company would be able to help you directly with this.

 

[TVP]

I agree with metengr-- Mr. Rao is extremely knowledgeable
& is an expert on large castings in unusual alloys.

 

[arunmrao]

tc 7

manufacturing one off castings need special skills and enterprise. Not many would be interested in undertaking such a task. Also the tooling cost (pattern+ corebox) adds upto the opportunity cost.

If the pot is a stationary one, you can consider some of the ceramic,graphite or silicon carbide pots available off the shelyf Else your local Foseco representative maybe able to guide you. Failing all possibilities,you may contact me and I shall try to my best. my id is my handlename at hotmail. Hope you get the hint.

I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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[tc7]

got it, and that is what I was fishing for.
thanks

 

[arunmrao]

tc7 did you catch the right fish?

I have not failed. I've just found 10,000 ways that won't work." — Thomas Edison
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