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Weld Surfacing Process for Main Cutter Disk

(1) Process Parameters:
Considering the characteristics of the main cutter disk, production efficiency, and reduction of dilution rate, electrode 4102 with a diameter of ±4mm is selected. The AX5-500 DC welding machine with stable arc performance is used. DC reverse polarity connection is adopted, with a welding current of 160A.

(2) Precautions:

1. Before welding, remove oxide skin, rust, moisture, and oil contamination from the parts to be welded.

2. If the main cutter disk is welded after bucket surfacing, the deformation caused by surfacing will be difficult to correct. Therefore, surfacing should be performed before the main cutter disk is assembled and welded to the bucket.

3. Due to the long and thin shape of the main cutter disk, deformation is easily caused during surfacing, and it is difficult to correct. To prevent welding deformation, fix the main cutter disk on a highly constrained metal frame before surfacing, and adopt a split and split-back welding method for welding.

4. To improve productivity and reduce dilution rate, downhill welding should be used.

5. If deformation occurs during surfacing of the main cutter disk, it should be flattened using a hydraulic press.

After surfacing, the hardness of the surfacing layer should be greater than HRC50.