Welding Alloys takes pride not only in providing an extensive range of advanced cored welding wires, but also in its commitment to offering technical support to customers. The team from Welding Alloys Panamericana recently showcased this commitment through on-site collaboration with a key customer in the hydropower sector. The objective was to offer the customer an alternative solution more tailored to their application. The team suggested a cored wire known for its exceptional weldability, making it well-suited for both complex and standard applications. Welding Alloys demonstrated the superiority of its cored welding wire compared to their existing solution for the turbine. The team also provided hands-on support in the welding and testing processes at the customer’s facilities in Mexico, using our CHROMECORE M 410 NiMo-G joining cored wire.
A technical visit was carried out for a week in November 2023, with a direct focus on the application of the CHROMECORE M 410 NiMo-G product on their turbines for projects that they currently had in progress.
Day one consisted of various weldability tests being conducted on plates with the wire in different positions—horizontal and vertical. All of the customer’s welders participated, and the results were promising. The filler material demonstrated excellent performance in various positions and handling. Notably, the applied beads were practically perfect, without welding defects, even on a base metal in poor condition (uncleaned).
On day two, the direct application of the wire commenced on two turbines, concentrating on two main points where erosion and cavitation were occurring and the welding showed promising results. The team from Welding Alloys closely supported the welders throughout the entire process, from material opening / set-up to component application, extending across different shifts in operations.
After a successful start to the welding process, on the third day, the team continued to support the customer with the welding of the turbines, right from the start of the first shift. It was clear that using CHROMECORE M 410NiMo-G improved performance and efficiency during application of the wire. The process covered a larger area in a shorter time, minimizing the need for prolonged periods in uncomfortable positions within confined spaces and exposure to high temperatures and fumes. Notably, the absence of scale, sparking, pores, cracks, and any welding defects in the turbine application eliminated the necessity for constant mechanical cleaning between welding beads.
Day four concluded that the wire was behaving as expected when applied to the component in different positions, and there were no problems. They had, however, identified a couple of cracks in the welds that has already been applied with another brand of welding wire, which were eliminated by removing the existing material and applying the Welding Alloys wire.
On the final day, the blade closures were welded, applied in direct contact with another brand’s wire. The outcome was excellent adhesion, with complete compatibility and no welding defects observed. The welding behaviour of the wire proved to be extremely user-friendly and manageable, resulting in a nice visual appearance after the wire was applied to the turbines. The positive results combined with the exceptional support provided by Welding Alloys, ensured a favourable attitude among welders towards the change. Furthermore, weldability tests were conducted using TIG filler material of the 410 NiMo alloy in 1.2 mm and 3.2 mm diameters. During these tests, two supervisors and the welder of the customer were present. Instantly, further applications for specific repairs on the turbine were identified.
After spending a week with the customer on-site, CHROMRECORE M 410NiMo-G stood out as the preferred welding wire. Welding Alloys provided comprehensive support to the customer throughout the entire process, ensuring the identification of the best solution tailored to their specific needs.
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