Salvaging a EN24 grade steel casting

[arunmrao]

I have recently cast a ring with a desired OD1140mm and iD 620mm,and thickness 50mm. This has now been found to measure 1131on OD with the ID having sufficient stock. The casting has shrunk more than expected,(which will be a separate topic).


I need to salvage the casting by depositing weld metal on the OD before I take up for machining. E7018 is the welding consumable,process is CO2 welding.

This is part of a tool for forming and OD1128mm is critical dimension as against it the component is formed.

Your comments please on such a salvage operation or is it better to recast?

Thanks in anticipation.

Chocolates,men,coffee: are somethings liked better rich!!
(noticed in a coffee shop)

 

[unclesyd]

I don't see why that will not work. We used to get 1030 castings that had weld repairs. We had no problem if the repair wasn't in an active area of the part. If the area was active we would evaluate each on a case by case basis. If the section was used for setting a location or just occupied space no question.

 

[arunmrao]

Unclesyd,
Thanks for the encouragement. eventually the run out was not much and I could salvage the casting with minimum welding.

Chocolates,men,coffee: are somethings liked better rich!!
(noticed in a coffee shop)

 

[unclesyd]

arunmrao,

The following violates our no weld in the working area rule.
Just though about some 1030 high pressure (10,000 psig) valve bodies where we would rework the cage area by weld repair. I do believe that we would stress relieve them at 1100F after welding. At the time stress relief was the same as PWHT. We used 7018 electrodes until about a year before we shut the process down when we went Hast C for the repair. The Hast C stopped all the wire drawing that necessitated the repair.

 

[moldcore]

I wonder if something like this could be salvaged by heating it up and letting it cool over a large ring or plug that has been machined to the size needed on the ID. I know this is done in the foundry business all the time to make castings round. Stretching it 9mm is not much over 1140mm but is a huge amount to weld. If, however the 620mm ID is good and can’t be increased enough to clean up then it’s toast.

 

[mfgenggear]

if this casting is not reworked/repaired yet!!!

Moldcore is actually has a good Idea :/, except check with a sheet metal forming shop that can set you casting in a expanding mandrel. if you have enough stock in the I.D., solution anneal the material dead soft, then expand/strech it to the required diameter. :\
I bet the I.D. contract as well as the O.D. which would alloy you to expand it.

I use to round up roll formed and welded steel plate this way.

Please Advise

 

[arunmrao]

Thanks moldcore ,mfgenggear,for your valuable suggestions. I have completed the salvage operations. But I shall surely remember to take this clue if I encounter similar problem again.

Chocolates,men,coffee: are somethings liked better rich!!
(noticed in a coffee shop)

 

[mfgenggear]

Glad all is well

Take care

 

[unclesyd]

arunmrao,
You may have to invest in a ring rolling machine.