WeldingAlloysGroup

WA Applicationsfor Sugar Cane

We’ve got your fix!We provide tailored solutions to increase the performance of your equipment

u Effect of wear 4 Decreased service life of the wear components

Impact of hardfacing on key components (e.g. Mills and Shredders)

Period 1: time taken to reach the optimum grinding phase.

Period 2: period of greatest efficiency, optimum conditions. The longer the process operates under these optimum conditions, the lower the operating cost per ton.

Period 3: period of excessive wear, increased cost per ton to produce.

Increasing the duration of Period 2 is achieved by applying the right hardfacing solution to the respective key components.

Impact of ‘Arcing’ on mill extraction

u Preparation of the grinding roll in order to extend service life

Example: On days 5 and 16, arcing is appliedResults: 30% decrease of brix by applying special ‘arcing’

TEAR DROPROBOCANE K ZUCARMAX EXTRACT PLUSMAX EXTRACT

SIDEBuild up:HARDFACE BUF-OHARDFACE UCW-OHardfacing Layer:MAX EXTRACT

SPATTERROBOCANE K ZUCARMAX EXTRACTMAX EXTRACT PLUS

MAX EXTRACT PLUS provides at least 50-60% more service life, when compared to all standard arcing solutions, and extraction rates up to 97-98%

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

0 5 10 15 20 25

°Brix

Days

OPTIMUM

ACTUAL

T1 T2 T30

En

E0

E1

STA

GE

1

STA

GE

2

STA

GE

3

Time, h

Spec

ific

Elec

tric

al C

onsu

mpt

ion,

kW

h/t

Product designation

Process O: Open arcE: ElectrodesTE: Tubular electrodes

ApplicationHardness as

welded (work hardened)

SPECIFIC SUGAR APPLICATIONS

MAX EXTRACT OTE Spatter 61 HRC t t

MAX EXTRACT PLUS O Tear drop and Spatter 63 HRC tt tt

HARDFACE BUF O Build-Up 250 HB t tt tt

HARDFACE UCW O Buffer layer / Rebuilding 180 HB (47 HRC) t tt tt tt

GENERAL MAINTENANCE APPLICATIONSGROOVALLOY O Gouging

HARDFACE TIC O Hardfacing 57 HRC t tt

HARDFACE DIAMOND O Hardfacing 63 HRC tt t

CAST NICI O Repairing of cast iron 190 HB t t t t

TRI S 312 O Dissimilar welding 260 HB t t tt t

HARDFACE AP O Build-up and repair 220 HB (50 HRC) t tt tt tt t

Min

eral

ab

rasi

on

Impa

ct

Met

al /

Met

al

frict

ion

Cor

rosi

on

Mac

hina

ble

WA Consumables The go-to provider of advanced welding consumables tSuitable ttHighly Suitable

WA Group offers copper-coated seamless cored wire, ROBOCANE, that provides great feedability and rust resistance.

Rebuilding on side on grinding teeth

Rebuilding over base/ Overlay - Laminate

Picote/Tear Drop Arcing in production (with and without

bypass)

Arcing in the workshop

WA Machines The go-to provider of automated equipment for wear protection

u SMK NG 4 Sugar Mill Kit New Generation

• Easy to operate• Tool-less onsite assembly• Increased efficiency through independent twin wire feed system • Reproducibility• Roll rebuild – during service (with/without cane bypass)

u TOPCASE 425-4 4 Stretch your productivity• Semi-automatic welding process• All-terrain wire feeder: Outdoor and indoor • Less stop and start - High productivity• Optimized operability & less defects• Easy to use

Existing MMA power source

TOPCASE 425-4

TOPTORCH 300-4E

Special sugar Torch1500 mm

Apr

il 20

18

WeldingAlloysGroup

WA Applicationsfor Sugar Cane

We’ve got your fix!We provide tailored solutions to increase the performance of your equipment

u Effect of wear 4 Decreased service life of the wear components

Impact of hardfacing on key components (e.g. Mills and Shredders)

Period 1: time taken to reach the optimum grinding phase.

Period 2: period of greatest efficiency, optimum conditions. The longer the process operates under these optimum conditions, the lower the operating cost per ton.

Period 3: period of excessive wear, increased cost per ton to produce.

Increasing the duration of Period 2 is achieved by applying the right hardfacing solution to the respective key components.

Impact of ‘Arcing’ on mill extraction

u Preparation of the grinding roll in order to extend service life

Example: On days 5 and 16, arcing is appliedResults: 30% decrease of brix by applying special ‘arcing’

TEAR DROPROBOCANE K ZUCARMAX EXTRACT PLUSMAX EXTRACT

SIDEBuild up:HARDFACE BUF-OHARDFACE UCW-OHardfacing Layer:MAX EXTRACT

SPATTERROBOCANE K ZUCARMAX EXTRACTMAX EXTRACT PLUS

MAX EXTRACT PLUS provides at least 50-60% more service life, when compared to all standard arcing solutions, and extraction rates up to 97-98%

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

0 5 10 15 20 25

°Brix

Days

OPTIMUM

ACTUAL

T1 T2 T30

En

E0

E1

STA

GE

1

STA

GE

2

STA

GE

3

Time, h

Spec

ific

Elec

tric

al C

onsu

mpt

ion,

kW

h/t

Product designation

Process O: Open arcTE: Tubular electrodes

ApplicationHardness as

welded (work hardened)

SPECIFIC SUGAR APPLICATIONS

MAX EXTRACT OTE Spatter 61 HRC t t

MAX EXTRACT PLUS O Tear drop and Spatter 63 HRC tt tt

HARDFACE BUF O Build-Up 250 HB t tt tt

HARDFACE UCW O Buffer layer / Rebuilding 180 HB (47 HRC) t tt tt tt

GENERAL MAINTENANCE APPLICATIONSGROOVALLOY O Gouging

HARDFACE TIC O Hardfacing 57 HRC t tt

HARDFACE DIAMOND O Hardfacing 63 HRC tt t

CAST NICI O Repairing of cast iron 190 HB t t t t

TRI S 312 O Dissimilar welding 260 HB t t tt t

HARDFACE AP O Build-up and repair 220 HB (50 HRC) t tt tt tt t

Min

eral

ab

rasi

on

Impa

ct

Met

al /

Met

al

frict

ion

Cor

rosi

on

Mac

hina

ble

WA Consumables The go-to provider of advanced welding consumables tSuitable ttHighly Suitable

WA Group offers copper-coated seamless cored wire, ROBOCANE, that provides great feedability and rust resistance.

Rebuilding on side on grinding teeth

Rebuilding over base/ Overlay - Laminate

Picote/Tear Drop Arcing in production (with and without

bypass)

Arcing in the workshop

WA Machines The go-to provider of automated equipment for wear protection

u SMK NG 4 Sugar Mill Kit New Generation

• Easy to operate• Tool-less onsite assembly• Increased efficiency through independent twin wire feed system • Reproducibility• Roll rebuild – during service (with/without cane bypass)

u TOPCASE 425-4 4 Stretch your productivity• Semi-automatic welding process• All-terrain wire feeder: Outdoor and indoor • Less stop and start - High productivity• Optimized operability & less defects• Easy to use

Existing MMA power source

TOPCASE 425-4

TOPTORCH 300-4E

Special sugar Torch1500 mm

Apr

il 20

18

WeldingAlloysGroup

WA Applicationsfor Sugar Cane

We’ve got your fix!We provide tailored solutions to increase the performance of your equipment

u Effect of wear 4 Decreased service life of the wear components

Impact of hardfacing on key components (e.g. Mills and Shredders)

Period 1: time taken to reach the optimum grinding phase.

Period 2: period of greatest efficiency, optimum conditions. The longer the process operates under these optimum conditions, the lower the operating cost per ton.

Period 3: period of excessive wear, increased cost per ton to produce.

Increasing the duration of Period 2 is achieved by applying the right hardfacing solution to the respective key components.

Impact of ‘Arcing’ on mill extraction

u Preparation of the grinding roll in order to extend service life

Example: On days 5 and 16, arcing is appliedResults: 30% decrease of brix by applying special ‘arcing’

TEAR DROPROBOCANE K ZUCARMAX EXTRACT PLUSMAX EXTRACT

SIDEBuild up:HARDFACE BUF-OHARDFACE UCW-OHardfacing Layer:MAX EXTRACT

SPATTERROBOCANE K ZUCARMAX EXTRACTMAX EXTRACT PLUS

MAX EXTRACT PLUS provides at least 50-60% more service life, when compared to all standard arcing solutions, and extraction rates up to 97-98%

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

0 5 10 15 20 25

°Brix

Days

OPTIMUM

ACTUAL

T1 T2 T30

En

E0

E1

STA

GE

1

STA

GE

2

STA

GE

3

Time, h

Spec

ific

Elec

tric

al C

onsu

mpt

ion,

kW

h/t

Product designation

Process O: Open arcTE: Tubular electrodes

ApplicationHardness as

welded (work hardened)

SPECIFIC SUGAR APPLICATIONS

MAX EXTRACT OTE Spatter 61 HRC t t

MAX EXTRACT PLUS O Tear drop and Spatter 63 HRC tt tt

HARDFACE BUF O Build-Up 250 HB t tt tt

HARDFACE UCW O Buffer layer / Rebuilding 180 HB (47 HRC) t tt tt tt

GENERAL MAINTENANCE APPLICATIONSGROOVALLOY O Gouging

HARDFACE TIC O Hardfacing 57 HRC t tt

HARDFACE DIAMOND O Hardfacing 63 HRC tt t

CAST NICI O Repairing of cast iron 190 HB t t t t

TRI S 312 O Dissimilar welding 260 HB t t tt t

HARDFACE AP O Build-up and repair 220 HB (50 HRC) t tt tt tt t

Min

eral

ab

rasi

on

Impa

ct

Met

al /

Met

al

frict

ion

Cor

rosi

on

Mac

hina

ble

WA Consumables The go-to provider of advanced welding consumables tSuitable ttHighly Suitable

WA Group offers copper-coated seamless cored wire, ROBOCANE, that provides great feedability and rust resistance.

Rebuilding on side on grinding teeth

Rebuilding over base/ Overlay - Laminate

Picote/Tear Drop Arcing in production (with and without

bypass)

Arcing in the workshop

WA Machines The go-to provider of automated equipment for wear protection

u SMK NG 4 Sugar Mill Kit New Generation

• Easy to operate• Tool-less onsite assembly• Increased efficiency through independent twin wire feed system • Reproducibility• Roll rebuild – during service (with/without cane bypass)

u TOPCASE 425-4 4 Stretch your productivity• Semi-automatic welding process• All-terrain wire feeder: Outdoor and indoor • Less stop and start - High productivity• Optimized operability & less defects• Easy to use

Existing MMA power source

TOPCASE 425-4

TOPTORCH 300-4E

Special sugar Torch1500 mm

Apr

il 20

18

A Welding Alloys solution for every step of the process

1 1 1 1 2 2 2 3

3 3 4 4 4

Sugarcane HarvesterMAX EXTRACT

Side platesHARDFACE DIAMONDMAX EXTRACTMAX EXTRACT PLUS

Cutting diskHARDFACE DIAMONDMAX EXTRACT

RollerHARDFACE DIAMONDMAX EXTRACT

Cane LoaderHARDFACE DIAMONDMAX EXTRACT

KickersHARDFACE DIAMONDMAX EXTRACT

GearHARDFACE UCW-OHARDFACE AP-O

Shredder diskHARDFACE DIAMONDHARDFACE TIC-O

Anvil HARDFACE DIAMONDHARDFACE TIC-O

HammerHARDFACE DIAMONDHARDFACE TIC-O

Knife holderHARDFACE DIAMONDMAX EXTRACT

KnifeHARDFACE DIAMOND

Trash plateHARDFACE UCW-OHARDFACE DIAMOND

Gear / CogwheelHARDFACE AP-O

RollROBOCANE K ZUCARMAX EXTRACTMAX EXTRACT PLUS

FanHARDFACE DIAMONDHardPlate 100Hardlite

5

Harvesting1 Extraction Station4 5

Cane Receival 2

3Defibration Boiler - Power Generation

3

33 4

Mill side platesMAX EXTRACT

WeldingAlloysGroup

WA Applicationsfor Sugar Cane

We’ve got your fix!We provide tailored solutions to increase the performance of your equipment

u Effect of wear 4 Decreased service life of the wear components

Impact of hardfacing on key components (e.g. Mills and Shredders)

Period 1: time taken to reach the optimum grinding phase.

Period 2: period of greatest efficiency, optimum conditions. The longer the process operates under these optimum conditions, the lower the operating cost per ton.

Period 3: period of excessive wear, increased cost per ton to produce.

Increasing the duration of Period 2 is achieved by applying the right hardfacing solution to the respective key components.

Impact of ‘Arcing’ on mill extraction

u Preparation of the grinding roll in order to extend service life

Example: On days 5 and 16, arcing is appliedResults: 30% decrease of brix by applying special ‘arcing’

TEAR DROPROBOCANE K ZUCARMAX EXTRACT PLUSMAX EXTRACT

SIDEBuild up:HARDFACE BUF-OHARDFACE UCW-OHardfacing Layer:MAX EXTRACT

SPATTERROBOCANE K ZUCARMAX EXTRACTMAX EXTRACT PLUS

MAX EXTRACT PLUS provides at least 50-60% more service life, when compared to all standard arcing solutions, and extraction rates up to 97-98%

0.8

0.9

1

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

0 5 10 15 20 25

°Brix

Days

OPTIMUM

ACTUAL

T1 T2 T30

En

E0

E1

STA

GE

1

STA

GE

2

STA

GE

3

Time, h

Spec

ific

Elec

tric

al C

onsu

mpt

ion,

kW

h/t

Product designation

Process O: Open arcE: ElectrodesTE: Tubular electrodes

ApplicationHardness as

welded (work hardened)

SPECIFIC SUGAR APPLICATIONS

MAX EXTRACT OTE Spatter 61 HRC t t

MAX EXTRACT PLUS O Tear drop and Spatter 63 HRC tt tt

HARDFACE BUF O Build-Up 250 HB t tt tt

HARDFACE UCW O Buffer layer / Rebuilding 180 HB (47 HRC) t tt tt tt

GENERAL MAINTENANCE APPLICATIONSGROOVALLOY O Gouging

HARDFACE TIC O Hardfacing 57 HRC t tt

HARDFACE DIAMOND O Hardfacing 63 HRC tt t

CAST NICI O Repairing of cast iron 190 HB t t t t

TRI S 312 O Dissimilar welding 260 HB t t tt t

HARDFACE AP O Build-up and repair 220 HB (50 HRC) t tt tt tt t

Min

eral

ab

rasi

on

Impa

ct

Met

al /

Met

al

frict

ion

Cor

rosi

on

Mac

hina

ble

WA Consumables The go-to provider of advanced welding consumables tSuitable ttHighly Suitable

WA Group offers copper-coated seamless cored wire, ROBOCANE, that provides great feedability and rust resistance.

Rebuilding on side on grinding teeth

Rebuilding over base/ Overlay - Laminate

Picote/Tear Drop Arcing in production (with and without

bypass)

Arcing in the workshop

WA Machines The go-to provider of automated equipment for wear protection

u SMK NG 4 Sugar Mill Kit New Generation

• Easy to operate• Tool-less onsite assembly• Increased efficiency through independent twin wire feed system • Reproducibility• Roll rebuild – during service (with/without cane bypass)

u TOPCASE 425-4 4 Stretch your productivity• Semi-automatic welding process• All-terrain wire feeder: Outdoor and indoor • Less stop and start - High productivity• Optimized operability & less defects• Easy to use

Existing MMA power source

TOPCASE 425-4

TOPTORCH 300-4E

Special sugar Torch1500 mm

Apr

il 20

18