Large steel axial cones are primarily used to transition between pipes of different diameters, handle bulk materials via gravity, and manage immense structural loads in various heavy industries.
As shown below, this cone came into our shop heavily damaged - without a tip and showing extensive cracking throughout.
These cones degrade primarily due to intense physical wear, aggressive corrosion, and cyclic structural stress.
When these factors cause significant metal loss or cracking, Fusion Industrial Laser Services utilizes robotic CMT welding to rebuild the dimensions and apply highly durable, corrosion and wear resistant alloys without risking the integrity of the base material.
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Before rebuilding the tip and refurbishing the cone's surface, we first machined off all cracks and defects to what is shown below.
We built up the tip of the cone using wire arc additive manufacturing (WAAM) - an advanced, large-scale metal 3D printing process that utilizes robotic MIG welding technology.
Once the tip was built up using a wear resistant alloy, we machined it down again
PART AND PROCESS INFO
Component: Axial Cone
Weight: 5,000lbs (approx.)
Overall Length: 56" (approx.)
Max Diameter: 14" (approx.)
Turnaround time: 7 days
Work Performed: Machining, WAAM, CMT Welding
ADVANTAGES
Cutting-Edge Facility - Our facility is one of the most complete complementary manufacturing partners in North America. Machining, welding, laser cladding and much more all done under one roof. Our work ranges from the microscopic, with parts weighing in grams, to macroscopic full-scale parts - weighing in at 25 metric tons.
State of the Art Methods - CMT (Cold Metal Transfer) welding is a modified MIG process featuring a wire that mechanically retracts during every short circuit. Its primary advantages over regular MIG are significantly faster travel speeds (up to 2x faster), higher deposition rates and significantly reduced heat input.
Reduced In-Service Downtime - Improved mechanical properties of the coating ensures maximum wear and corrosion resistance. This means cones wear down slower, allowing it to stay in service longer.
As shown above, we next applied layers of corrosion and wear resistant material using CMT welding.
We then machine finished the cone making it ready to be put back in service.
ABOUT US
For more than 40 years, Fusion Industrial Laser Services and our parent company Whitfield Welding Inc. have provided high-value repair, refurbishment, and part enhancement using cutting-edge laser and welding solutions for our customers in the automotive, mining/exploration, oil & gas, energy, aerospace, and defense industries.