https://www.precisioncastingrepair.com/home-1 daily 1.0 2021-05-28 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458123496-JY4MG8F77RGF7MQ031GT/Furnace_Welding_11.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458123678-SWOHL1TXFCIGZSS8SHZ9/Furnace_Welding_16.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458124804-STUQMSJ1CY1Z4YAUTEUI/Furnace_Welding_20.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458124800-HLJECO58AXWTZMNLIUGV/Furnace_Welding_22.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458125468-5FLS7ZULHJXUTOA4CCRM/Furnace_Welding_25.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458125777-SVFLA4NJ1U4MV8597XO0/Furnace_Welding_26.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458126148-BCNQG3JJZYQMR4E3WJAQ/Furnace_Welding_28.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458126366-61W3SVFPBK0RZNGE4YIL/Furnace_Welding_30.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458126766-4ODQBI9XL44GSV9HXRNL/Furnace_Welding_32.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458239971-E5KJU8NHWEXNYFYRVOX1/Furnace_Brazing_04.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458239868-E58I5CY0OM8LBF42CROU/Furnace_Brazing_05.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458241229-IG856163UNTS28LF6ASA/Furnace_Brazing_07.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458241795-EVSRMO7ADYCUKXC0FA2X/Furnace_Brazing_10.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458242966-5SKR8WAZXIRM5E0A6BWZ/Furnace_Brazing_21.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458242822-JFJ8FJ2FN74Y97NZKA5X/Furnace_Brazing_24.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458244165-T7OP45EM1T0AQOA5ST94/Furnace_Brazing_26.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458320052-R1N58ANOBVK0SAPRFEU0/Gear_Repair_01.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458320064-ZXO1441SFVCNN2YRE7CF/Gear_Repair_02.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458320631-JK3FP9AGA6CQG1K1663I/Gear_Repair_03.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458320763-P8XCMVFF2L0UFR4JKUMR/Gear_Repair_04.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458321217-XFHH33ZR2G7DWTS802N4/Gear_Repair_05.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529458321275-DQ4MTOE3NW9KBN4VGK4R/Gear_Repair_06.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456168574-M1NHV8W5Y2QP1EHZC6MM/Ironstitch_Repair_03.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456169785-QKMRJEPJQ937Z3T7OSXA/Ironstitch_Repair_07.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456168589-2NZNVPQER8XYLOXR8FMB/Ironstitch_Repair_05.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456170402-7UA7GDILKHKS11BY3SHG/Ironstitch_Repair_08.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456169057-5KDDPW1V7SN49FKRYA8T/Ironstitch_Repair_06.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456170859-HPER2AQACPAAEZWB58G6/Ironstitch_Repair_09.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456171910-7ZRYPOT3DQLI9J9V6CPW/Ironstitch_Repair_11.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456172134-W83AGPSVBUZ5QFY8N0C6/Ironstitch_Repair_10.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456172959-SGZLM7K11K5R002IOSTH/Ironstitch_Repair_13.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456173308-WW7F5MOV7XVFOUZBROP4/Ironstitch_Repair_14.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529456174092-N7SQNQKQ95V7S0NX81R7/Ironstitch_Repair_15.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Home https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557770562-AAQ69880PPBEASOBAU7Y/Furnace_Brazing_04.jpg Home https://www.precisioncastingrepair.com/ironstitch-repair daily 0.75 2018-11-29 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529460191959-2JFKWCV8GS339ZHBLLBA/Ironstitch_Repair_01.jpg Ironstitch Repair - CRACKED CAST IRON GATE This is a cracked cast iron gate valve. It cracked due to freezing. This had to be repaired on-site as this tank held 10,000 gallons of water that supplied all of the water for the fire suppression system at the plant. By repairing it on-site they did not have to incur any unscheduled down time. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459769272-MZ6JKU9IAIQ51DJFZH86/Ironstitch_Repair_02.jpg Ironstitch Repair - CRACKED CAST IRON GATE This shows the crack before any of our Ironstitch repair was started. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459769696-VL4GJPN8GGWQ5UALNLSM/Ironstitch_Repair_03.jpg Ironstitch Repair - CRACKED CAST IRON GATE The Ironstitch Lock patterns are the first step of the repair process. The wall thickness determines how deep we can sink and stack our locks. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459769802-BIG9I5C6R6C7YKSQ5DFX/Ironstitch_Repair_04.jpg Ironstitch Repair - CRACKED CAST IRON GATE The Locks have been installed into the valve body which gives the strength to hold it together. The next step will be to install the first series of Ironstitch pins. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459770392-ZVA9G8DDC64R94FFCO5G/Ironstitch_Repair_05.jpg Ironstitch Repair - CRACKED CAST IRON GATE The first series of Ironstitch pins have been installed. Note the spacing allows room for only one more pin to be installed in between each other. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459770391-YECAUAXJTPY23UDAJNZW/Ironstitch_Repair_06.jpg Ironstitch Repair - CRACKED CAST IRON GATE The repair is now complete. As you can see, this has successfully repaired the valve with minimum cost to the customer. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459771750-XUZRV8YTEXRMFNPGS1NP/Ironstitch_Repair_07.jpg Ironstitch Repair - CRACKED CAST IRON GATE This shows how our Ironstitch Lock patterns are precisely drilled into a casting. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459771468-DGL4WNFCVIUU1C01WIKI/Ironstitch_Repair_08.jpg Ironstitch Repair - CRACKED CAST IRON GATE The crack was just over 1” deep. We don’t go much deeper than the bottom of the crack. We just make sure the crack is completely removed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459772677-0YL3EC7G16NKKKFOYUJ9/Ironstitch_Repair_09.jpg Ironstitch Repair - CRACKED CAST IRON GATE This lock is made from 3” thick heat treated 4140 material and is cut with a Wire EDM machine to make sure the tolerances are kept so that the lock will pull both sides of the crack back together. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459773283-EYRNPAJ3L8Y696MPWK9R/Ironstitch_Repair_10.jpg Ironstitch Repair - CRACKED CAST IRON GATE The lock is driven in to the full depth of the crack. The excess is cut off using a die grinder with a cut off wheel. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459773701-XUH0SD5P42NEJT1VFP2T/Ironstitch_Repair_11.jpg Ironstitch Repair - CRACKED CAST IRON GATE The Locks are all installed and the crack is checked using the Magnetic Particle crack detection process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459774600-YFAOYXRNGM3SK3R999JE/Ironstitch_Repair_12.jpg Ironstitch Repair - CRACKED CAST IRON GATE The Stitching Pin holes are now drilled and tapped in the casting in between the Locks that were previously installed. This picture shows us using one of our custom designed pneumatic drills that we have developed over the years. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459774639-JUMD3BAJ5AWITXCYXMWW/Ironstitch_Repair_13.jpg Ironstitch Repair - CRACKED CAST IRON GATE The first series of holes are drilled and tapped and now ready for the installation of the Stitching Pins. The pins are of various lengths so we can install them to the full depth of the repair. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459775971-WE7PXLSWNT08HNGOH5S1/Ironstitch_Repair_14.jpg Ironstitch Repair - CRACKED CAST IRON GATE The repair is complete and ready for finish grind. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459775865-XCDV6N5FL8T9W1K45BEV/Ironstitch_Repair_15.jpg Ironstitch Repair - CRACKED CAST IRON GATE The crack has been removed and the repair has been finish ground to conform to the shape of the original casting. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459776943-P08W2YQINUQ9AR68OJMQ/Ironstitch_Repair_16.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE This Dragline had a cracked tub near the center pin. Due to the location of the crack it could not be welded in place successfully. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459777203-2KLIO7WSUCHZYHCKTQSW/Ironstitch_Repair_17.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE This center pin supports the entire Dragline. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459779179-C82YB1184EQ8Z6JH4N0N/Ironstitch_Repair_18.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE The tub supporting the Center pin had approximately 10 feet of crack going radially around the Center pin. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459778349-SU4TF06SEKF9EDSLXZF8/Ironstitch_Repair_19.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE The Lock patterns have all been drilled. There was only 13 inches of space to work in. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459779183-YAFGV7ZRCSC77TFA75W3/Ironstitch_Repair_20.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE Because there was only 13” of clearance on this job, we had to design special pneumatic drills to be able to drill in such close quarters. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459780373-Q3L90ZVIZEEMSGF4P00J/Ironstitch_Repair_21.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE The Locks have been installed and the Stitching pins are in the process of being installed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459781026-Q85L0ZX2IQWO40OFOL23/Ironstitch_Repair_22.jpg Ironstitch Repair - DAMAGED TUB ON DRAGLINE The repair is completed and the Dragline is put back into service. This repair was completed in 7 days. Because there was no welding involved, there was absolutely no stress created in this repair. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459781636-0IJPTNNZAXCO47AALSQ6/Ironstitch_Repair_23.jpg Ironstitch Repair - CRACKED CASTING This is at a Power Plant in South Dakota. The casting had several large cracks in it. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459782886-C6JEZ8AZYZLT704S1HOB/Ironstitch_Repair_24.jpg Ironstitch Repair - CRACKED CASTING Because it is made from cast iron, and had to be repaired in place, the only method of repair was to use our Stitching method. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459782918-Z602XFNB822CR3A8M25N/Ironstitch_Repair_25.jpg Ironstitch Repair - CRACKED CASTING This is after the Locks had been installed and in the process of finishing this part of the crack. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459784663-K9REDG4MRI098YJ0DNJK/Ironstitch_Repair_26.jpg Ironstitch Repair - CRACKED CASTING This crack is finished and being ground in to conform to the casting. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459784144-87U7Y6BN4SVQ5V0K6E64/Ironstitch_Repair_27.jpg Ironstitch Repair - CRACKED CASTING This shows the longer crack with all the Locks installed and just finishing the second series of Stitching Pin installation. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529459786722-H3DDPLPJ877SS6Q5Y2Z6/Ironstitch_Repair_28.jpg Ironstitch Repair - CRACKED CASTING All the Locks and Stitching Pins are installed and ready for finish grinding to conform to the original shape of the casting. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Ironstitch Repair https://www.precisioncastingrepair.com/furnace-brazing daily 0.75 2018-11-29 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557769094-DXPT4HPQN4X955L6GQ6Y/Furnace_Brazing_01.jpg Furnace Brazing - BALL MILL HEAD This is a Ball Mill Head. The bearing journal seal areas were completely worn out. Because the Head is made from cast iron, we were able to rebuild it using our Furnace Brazing process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557768730-W62SZX963SRL4S8M9RHR/Furnace_Brazing_02.jpg Furnace Brazing - BALL MILL HEAD New seal areas were fabricated out of steel then Furnace Brazed into place. Because the brass we use is twice as strong as the cast iron and it bonds to both steel and cast iron, this produced a strong repair. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557770016-UILGB4S8YJIEK2UWQK8V/Furnace_Brazing_03.jpg Furnace Brazing - BALL MILL HEAD This is an example of how we preheated the Head to the proper temperature for Furnace Brazing. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557770562-AAQ69880PPBEASOBAU7Y/Furnace_Brazing_04.jpg Furnace Brazing - BALL MILL HEAD This shows our Furnace Brazing process. All of our brazing is done while the part is kept at the proper temperature. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557771251-CFYXCQWLP8DXC71ERSVA/Furnace_Brazing_05.jpg Furnace Brazing - BALL MILL HEAD This is the part after all of the Furnace Brazing was completed. It’s now ready for finish machining. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557772684-KOBW8BET2Q9ZQVINZOU6/Furnace_Brazing_06.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This is a cast iron bearing pedestal with a broken flange. The broken piece is shown sitting on the base. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557772428-6M1LRNYV16B6N0NFLBPT/Furnace_Brazing_07.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This shows the broken flange after the Furnace Brazing and machine work was completed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557773224-EKYBKVB5M9NFL89JXDGI/Furnace_Brazing_08.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This horizontal split pump had been previously repaired by another company using a nickel welding process. As you can see by the dye it did not fully bond to the cast iron. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557774527-CC31LHR15B9XNMCFF3AS/Furnace_Brazing_09.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL All of the old Nickel had to be removed. The pump is now ready to be Furnace Brazed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557774973-BIWJP1LSBERU1H4BTPCZ/Furnace_Brazing_10.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL The pump is put in the oven and it’s ready for pre-heat to the desired temperature. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557776569-BUE6KENO12BZ9XOWYGPB/Furnace_Brazing_11.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This is what it looks like after the completion of our Furnace Brazing process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557776749-TPNU321IOU58NTOBRH8X/Furnace_Brazing_12.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL The pump has been surface ground flat is now ready tor the finish line bore work. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557777768-T9TKCN67X9IX8KMIL324/Furnace_Brazing_13.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This gearbox suffered a major failure. Sometimes it’s necessary to rebuild something this damaged due to the fact that the part is no longer available. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557778127-LIKEBURS893DGATDO0GC/Furnace_Brazing_14.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL The gearbox is all finished and ready for paint. All of the bores needed to be line bored. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557778336-O5TW0AWWDSEW4L1IPXC6/Furnace_Brazing_15.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL This Press Guide was broken in half. This is in the prepped stages for Furnace Brazing. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557778710-QP7881XGMJ1HK3LSLHR0/Furnace_Brazing_16.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL After Furnace Brazing the part was ground to conform to the original shape. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557778939-H8VRI5D82BTYAV3QLEJZ/Furnace_Brazing_17.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL After the machine work was completed, the part was checked again for any cracking prior to detailing and paint. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557779215-CYJNQUCAGDA3R01SDGMM/Furnace_Brazing_18.jpg Furnace Brazing - CAST IRON BEARING PEDESTAL The part is now finished and ready for installation. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557780358-N7GRCJR42HF6UT5W7A7B/Furnace_Brazing_19.jpg Furnace Brazing - CONNECTING ROD This is a connecting rod off of a punch press. The rod pin bore was fractured in 4 directions along with the bore being out of round. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557780721-VJFZVZFPE5B1GR82XO3B/Furnace_Brazing_20.jpg Furnace Brazing - CONNECTING ROD We removed the damaged rod eye completely and machined the rod end to accept a new steel slug. This is an application that we can make the part stronger than new by attaching steel instead of cast iron. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557781937-EK68VLQLPK99WCLP914B/Furnace_Brazing_21.jpg Furnace Brazing - CONNECTING ROD An alignment dowel was machined and installed to create a way to center the slug perfectly. We also added a grease port so the new rod end could be greased which wasn’t part of the original design. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557781724-WBTCSL57KRK3J1XSIUFO/Furnace_Brazing_22.jpg Furnace Brazing - CONNECTING ROD The rod was prepped to receive the slug end. Notice the machined area prepped to receive the aligning dowel. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557782738-IMMTPGNH6TQQ0RJZPQAC/Furnace_Brazing_23.jpg Furnace Brazing - CONNECTING ROD A fixture was made to hold the slug end in place prior to Furnace Brazing. This ensures perfect alignment during the Furnace Brazing process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557783088-SNASYYFEQ2W0Y15TI2HI/Furnace_Brazing_24.jpg Furnace Brazing - CONNECTING ROD The part is in the process of being Furnace Brazed. Notice how everything is maintained at a consistent temperature. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557784456-6GEUU2345L79LR9RXUTV/Furnace_Brazing_25.jpg Furnace Brazing - CONNECTING ROD This is the part after the completion of the Furnace Brazing and finish grinding. It’s now ready to be finish machined. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557784349-EJWKSLKMPR08GQ8Y2ON1/Furnace_Brazing_26.jpg Furnace Brazing - CONNECTING ROD New bushings were installed on the crank bore. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557784902-7982AY9X4MWA12XL45F1/Furnace_Brazing_27.jpg Furnace Brazing - CONNECTING ROD The job is completed and assembled. We previously repaired this piston seven years ago and it has been running continually since then with no issues. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557785650-HSJSV9VW9LS6H0Y5Y654/Furnace_Brazing_28.jpg Furnace Brazing - CONNECTING ROD We repaired the pin bore by sleeving and line boring the piston. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Furnace Brazing https://www.precisioncastingrepair.com/gear-repair daily 0.75 2018-11-29 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555073845-U5F3Y0V63M0YVKN6SZSV/Gear_Repair_01.jpg Gear Repair - LARGE BULL GEAR This is a large ball mill that had damage to the large bull gear. This is at a gold mine in Kyrgyzstan. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555073933-7RR7EEKWOASFOUGRJAHJ/Gear_Repair_02.jpg Gear Repair - LARGE BULL GEAR This gear had a broken tooth and the damage was spreading to the other teeth. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555074304-RQMQ1M1Y3O9N94BBRRI6/Gear_Repair_03.jpg Gear Repair - LARGE BULL GEAR After the tooth was prepped for welding, we pre-heated the gear to the proper temperature before any welding was performed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555074406-SVVR2RY7J6FFO0CF8CWG/Gear_Repair_04.jpg Gear Repair - LARGE BULL GEAR After the gear was preheated, all of the welding was carried out. Upon completion of the welding process, the temperature of the gear was slowly ramped down. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555074901-MLCEPXNM5IADSY0RXQVL/Gear_Repair_05.jpg Gear Repair - LARGE BULL GEAR This shows what the rebuilt tooth looked like after the gear cooled down. As you can see we try to maintain the original shape of the tooth to minimize the finish work. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555075028-OE08NE5XJAZX79SMNLNR/Gear_Repair_06.jpg Gear Repair - LARGE BULL GEAR We made a mold that reflects the current wear pattern of the gear. We ground the new tooth to fit that wear pattern. By doing it this way there will not be any high spots in our repair. The gear repair is completed and ready to go back into service. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555076947-9NRK674IQ1X21RC6DQ9F/Gear_Repair_07.jpg Gear Repair - CAST IRON GEAR This cast iron gear is from a manufacturing plant. The teeth were completely worn out. We removed the old cast iron ring and installed a new steel ring using our Furnace Brazing process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555076508-89BC2Y6650Z6Z435D2N5/Gear_Repair_08.jpg Gear Repair - CAST IRON GEAR The gear is completed and ready to be shipped back to the customer. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555077414-VKQ45WI34ZGFGZZI5719/Gear_Repair_09.jpg Gear Repair - LARGE CONVERTER GEAR This is a large converter gear from a copper processing plant. It has 256 internal teeth and is 17 feet in diameter. All of the teeth needed to be rebuilt. This is one of four converter gears we repaired for them. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555077915-AUFJW5JVDGNMBG09YECH/Gear_Repair_10.jpg Gear Repair - LARGE CONVERTER GEAR This is the condition of the teeth before we started. Some of the teeth were cracked as seen by the arrow. Because of the location of this gear it was not feasible to replace it and the only option was to repair it on-site. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555078893-BHFDXLLG1GPXZ6TX5TVH/Gear_Repair_11.jpg Gear Repair - LARGE CONVERTER GEAR A template was manufactured from the dimensions off of a drawing that was provided to us. It was designed to be adjustable to line up the teeth. We started with it set on the best teeth available. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555078987-H2XG1TTS2XFCCHVC2SZV/Gear_Repair_12.jpg Gear Repair - LARGE CONVERTER GEAR This shows how we were able to adjust the template to line up the existing teeth. Once we locked it in place, we kept that location of the template all the way around the gear. As you can see, even the best teeth were in very bad shape. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555079787-9BL99HOAJCVBRQ81KC4X/Gear_Repair_13.jpg Gear Repair - LARGE CONVERTER GEAR This shows the template in place and ready to start. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555079786-A96W5IH3Z2QKXMNBZROO/Gear_Repair_14.jpg Gear Repair - LARGE CONVERTER GEAR After the welding was completed, we rough ground the welds in preparation for the machine work. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555080945-2QIYVAX8S45OM2I5T5HD/Gear_Repair_15.jpg Gear Repair - LARGE CONVERTER GEAR After the welding and rough grinding was completed on the teeth, we set up our portable milling machine on the fixture that we engineered for this job. We were able to make the teeth uniform to match the print. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529555080762-5175MXHJ1IJ7TRQLI2ML/Gear_Repair_16.jpg Gear Repair - LARGE CONVERTER GEAR As it was completed, we checked it by running it through the double pinion drive system. The customer was finally able to properly set the backlash on the gears. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Gear Repair https://www.precisioncastingrepair.com/furnace-welding daily 0.75 2018-11-29 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557650610-GYLXUO4DZC94NOG4R3XH/Furnace_Welding_01.jpg Furnace Welding - AMP-800 ADJUSTMENT RING This is an Adjustment Ring for a MP-800 secondary crusher. Besides the break (which was all the way through) the threads were completely worn out. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557650391-618P2I839P3I3K8EVBDT/Furnace_Welding_02.jpg Furnace Welding - CRACKED CAST IRON GATE This is the view of the adjustment ring from the outside. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557651823-FU53I7YBEUL9RL5KMKRN/Furnace_Welding_03.jpg Furnace Welding - WELDING POSITIONER With our large welding positioner, we can handle up to 50,000 lbs and up to 15 feet in diameter. This is an adjustment ring from a crusher with bad threads and seat areas. We were able to put on enough material to completely recondition this part, saving the customer from having to buy new. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557652130-9TV881WBZWSXUAM3JBDR/Furnace_Welding_04.jpg Furnace Welding - WELDING POSITIONER Our welding positioner allows us to put the part on the correct angle to allow us to use our Sub Arc welding process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557653663-CDG53XC2ZC9JTBWAXS4Z/Furnace_Welding_05.jpg Furnace Welding - ADJUSTMENT RING This shows our Sub Arc process that we use to apply a large amount of welding wire with a single pass. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557655429-NB2FX4BA6HUETYY09NPH/Furnace_Welding_06.jpg Furnace Welding - ADJUSTMENT RING This is the finished build up and the part is now ready for finish machine work. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557655142-884J3RMI1RMC1HCDOZG0/Furnace_Welding_07.jpg Furnace Welding - ADJUSTMENT RING Adjustment Ring after final machining. This part is now at factory OEM specifications. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557656495-8O7TGVDE58BCM83RP2T2/Furnace_Welding_08.jpg Furnace Welding - ADJUSTMENT RING This is the Adjustment Ring after the assembly was completed with the Clamping Ring attached. The part is painted and ready for shipping back to the customer. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557656762-AAT0OMAVCSVPYQYVJANM/Furnace_Welding_09.jpg Furnace Welding - MP-800 SECONDARY CRUSHER This is a bowl from a MP-800 secondary crusher. All of the threads were worn out on the Outside Diameter of the bowl. This part weighs approximately 35,000 lbs. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557657928-0I5I43PJOF4ZZQWSEVCR/Furnace_Welding_10.jpg Furnace Welding - MP-800 SECONDARY CRUSHER This shows the thread build-up complete and ready for the machining process. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557657666-CNC79VCLO0RWBGSM2X13/Furnace_Welding_11.jpg Furnace Welding - MP-800 SECONDARY CRUSHER The crusher Bowl is now complete after machine work. This part was stress relieved after all the welding was done and before the machine work was started. We were able to save the customer tens of thousands of dollars versus buying new. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557659858-DICXXFUFAIJFU2LMZWO9/Furnace_Welding_12.jpg Furnace Welding - MP-800 SECONDARY CRUSHER This crusher main support housing was worn out. Because it is a cast piece, we had to perform a furnace weld build up which put the strength back into it. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557659594-WGL4HBC5EEN6V3WA2AIJ/Furnace_Welding_13.jpg Furnace Welding - MP-800 SECONDARY CRUSHER This template shows how much build up is needed. We made the template from a drawing given to us by the customer. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557660994-ROO76KTR7MMR4DMMFKA4/Furnace_Welding_14.jpg Furnace Welding - MP-800 SECONDARY CRUSHER This picture shows how we had to wrap the casting in order to properly preheat it. It keeps the desired heat in the part while it is being welded, it also keeps the heat off of the welder. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557660995-7XV7QX3PPMVW7C5F0ZQS/Furnace_Welding_15.jpg Furnace Welding - MP-800 SECONDARY CRUSHER Using our Furnace Welding procedure, we were able to weld build up putting “hundreds” of pounds of welding material on the support housing to bring it back to factory specifications. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557662842-T97RFOCNGFXJIQG0RJGE/Furnace_Welding_16.jpg Furnace Welding - MP-800 SECONDARY CRUSHER We were able to save the customer from a long lead time for a new part. This repair method also saved the customer thousands of dollars over buying new. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557662485-1YRM429RXSKV0DYM1M6Q/Furnace_Welding_17.jpg Furnace Welding - SYMONS CRUSHER HEAD This is a 7 foot Symons crusher head with a worn out Skirt. We are installing a new Skirt using our welding positioner and Sub Arc welding procedure. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557664170-OHEFPHBKKAXT2ZKSYJ6B/Furnace_Welding_18.jpg Furnace Welding - SYMONS CRUSHER HEAD This shows the thickness of the new Skirt along with showing the build up of the worn area adjacent to the Skirt. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557663534-CSUWYS5LMWUQ0ZG5089X/Furnace_Welding_19.jpg Furnace Welding - SYMONS CRUSHER HEAD Our Sub Arc process lays down very large and clean welds which allows us to rapidly build up the worn areas as well as attaching the new Skirt. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557664436-BPYF4UXLEXAJIS0B892Z/Furnace_Welding_20.jpg Furnace Welding - SYMONS CRUSHER HEAD The Head is completely machined and is shown with the new Baffle Ring and Skirt installed. This rebuild has given new life to the crusher at a very reduced cost to the customer. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557664626-BDWUXR8E11CCHSVR2Q5M/Furnace_Welding_21.jpg Furnace Welding - D-11 RIPPER TOOL BAR This is a Caterpillar Ripper Tool Bar from a D-11. This has to have all 6 of the pockets replaced along with replacing the entire end that was torn away. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557665528-7SUVZC0Z3ZLE513387P1/Furnace_Welding_22.jpg Furnace Welding - D-11 RIPPER TOOL BAR It is obvious that the operator hit something so hard or large that it broke the frame, taking the pockets with it. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557665658-C7NE3AV06ZL3X21J2B8C/Furnace_Welding_23.jpg Furnace Welding - D-11 RIPPER TOOL BAR The tool bar with the damaged end removed and the line bore machine set up to pre-machine the bores to be welded. Due to the movement of the part from the Furnace welding and stress relieving process, all of the bores will need to be welded and line bored. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557666370-I912J0Z3QD3SODMW3537/Furnace_Welding_24.jpg Furnace Welding - D-11 RIPPER TOOL BAR The backing plates are installed and ready for the pockets to be installed. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557666549-7PV44KEIBHE87ULK4CXQ/Furnace_Welding_25.jpg Furnace Welding - D-11 RIPPER TOOL BAR The pockets are fit onto the backing plates prior to welding. This ensures we will have a 100% weld penetration by burning into the backing plates. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557667198-YWE6GF78329541ZSKO1Y/Furnace_Welding_26.jpg Furnace Welding - D-11 RIPPER TOOL BAR The repaired end with the pockets tacked in place and ready for furnace welding. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557667372-00PVSIPF1QUXG7W0BB75/Furnace_Welding_27.jpg Furnace Welding - D-11 RIPPER TOOL BAR All of the pockets are tack welded in place and ready for Furnace Welding. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557667823-VNHPWQI2Q67Y3FVIEYO8/Furnace_Welding_28.jpg Furnace Welding - D-11 RIPPER TOOL BAR The tool bar is properly wrapped in insulating blanket, heated and the temperature is maintained throughout the welding process. This greatly reduces the stress from all the welding. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557668056-EAPE55TTUW2HZQ5KGKPU/Furnace_Welding_29.jpg Furnace Welding - D-11 RIPPER TOOL BAR These are typical of all our welds. Notice that we only run clean stringer beads while peening and needle scaling between each pass. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557668349-OIGJ8ASI946MJUQPVSAM/Furnace_Welding_30.jpg Furnace Welding - D-11 RIPPER TOOL BAR After the tool bar was stress relieved, it was Dye Penetrant checked for cracks, finish machined, sandblasted and is shown ready to paint. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557668539-QABRNDBJZK7DNMYKLWEU/Furnace_Welding_31.jpg Furnace Welding - D-11 RIPPER TOOL BAR This is a close-up of one of our welds prior to painting. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529557668970-6FKQG9X4BUE6HYIL6VJ4/Furnace_Welding_32.jpg Furnace Welding - D-11 RIPPER TOOL BAR The tool-bar is completed and ready for shipment. https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Furnace Welding https://www.precisioncastingrepair.com/contact-us daily 0.75 2024-01-17 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg Contact https://www.precisioncastingrepair.com/about-us daily 0.75 2024-05-16 https://images.squarespace-cdn.com/content/v1/5b1db662a9e02833a5843264/1529553298025-FTP9IAYTKSLVWIAYFUOA/PCR_Logo_Wide_01.jpg About