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WA MultiSurfacer TMAutomated RollCladding Technology

Technology Driven Roll CladdingReliableRepeatablePreciseAutomationAbout The BrochureThis Welding Alloys Machines brochure describes theinnovative features, benefits and integrated componentsof the MultiSurfacer TM and roll cladding machine range.Welding Alloys pioneered the design and manufactureof automated welding equipment; continually improvingdesign and build quality with over 40 years of experience.About Welding AlloysWelding Alloys Group is the world’s leading manufacturerof automated welding equipment and flux coredconsumables; providing specialised services in claddingand hardfacing.ContentsExecutive Summary 2D3-Touch Technology Introduction 3D3-Touch Technology 4Roll Cladding Machine Family 6Machines Under The Spotlight 8Welding Processes 11Taking it to the next level…D3-Touch from Welding Alloys is a new control technology for automation allowing effective and efficientimplementation of fully automated welding techniques and processes.Welding Alloys incorporates new technology into all MultiSurfacer machines improving performance and accuracyof the welding process. This technology complements the precision engineered mechanics resulting in maximumperformance from our welding machines.• OEM• Full mix of welding processes• Reduction in labour costs, post weld processing & weld setup time• Superior weld quality• Quick recall of saved parameters & positions• Precise speed & position control• Global support network2 3 Automated Roll Cladding Technology

D3-Touch Driven TechnologyControl System Benefits• Saves set-up time through the setting up ofrepeatable welding parameters• Provides precision welding - reducing material /welding consumables used• Productivity improvement through high efficiency /low downtime• System is simple to use and program with only therequirement for one operatorD3-Touch intuitive controls• Full traceability of materials used and the weldingprocess• Minimises human interference during production• Saves time and cost, increasing efficiency andreproducibilityD3-Touch weld parameter screenControl System Features• Touch screen, high degree of motion & processcontrol• Real-time synchronisation• Touch screen with intuitive GUI (Graphical UserInterface)• Integrated processingProgrammable & Customisable controls• Data logging functionality• Built-in condition monitoring facility• Self / remote diagnostics• Remote monitoringWeld conditions monitoring screen* Further details about D3-Touch areoutlined in a separate leaflet4 5 Automated Roll Cladding Technology

Roll Cladding Machine FamilyRoll CladdingWelding Alloys new roll cladding machines are designed tooperate and synchronise seamlessly with D3-Touch technology.The mechanical design stage for MultiSurfacer TM machinesincorporates 3D CAD modelling software and finite elementanalysis for stress and strain distribution.R500-MultiSurfacer TM (Simultaneouscladding of four small diameter rolls)The product features for the latest MultiSurfacer TM machines aredesigned to achieve perfect quality welded materials whilst theease of operator interaction and application requirements are keptat the centre of our design philosophy.Flexibility is a key feature of the MultiSurfacer TM machine rangeand includes:R1000 and R3000• Adaptability for open arc, submerged arc or gas shieldedwelding• Configured with single or multiple welding heads• Operate with single or twin wire for maximum productivityA WA laser scanner unit constantly monitors the roll diameterwhich gives an accurate reading resulting in an evenly finishedsurface, minimising the welding materials used and associatedcosts.Roll Cladder with Laser Scanning &Milling StationR6000+Roll Cladder with Preheating StationMilling UnitThe WA range of MultiSurfacer TM has the ability of being expanded;one of these modular expansions available is our WA Milling Unit.The unit provides a rough machined finish during the final weldpass of the process. By carrying out the machining during the finalweld pass, the roll still carries residual heat allowing the unit tocut through a softer material, extending its life and increasing theproduction efficiency.• Easier machining due to softer material• Prolongs life of the cutting tool• Reduces additional processing of roll• Reduces overall expenditure in manufacturing the rollPreheatingMultiSurfacer TM preheating station benefits include:• Provides necessary preheating of component• Uses existing roll manipulation system with the preheaterunderneath the roll to maintain preheat and interpasstemperatures• Superior quality welded components6 7 Automated Roll Cladding TechnologyBespoke machine specifications are available to orderWA Roll Cladding MachinesSPECIFICATION Rolls R500 R1000 R3000 R6000 R12000 R20000 R50000Maximum componentweight (kg)Maximum unsupportedcomponent length (mm)Maximum componentdiameter (mm)X 2 Welding head oscillationmaximum travel (mm)Single 500 1000 3000 6000 12000 20000 50000Twin 2 x 500 2 x 1000 2 x 3000 2 x 6000 2 x 12000 2 x 20000 2 x 50000Single 1000 1200 2000 3000 3000 10000 10000Single 300 500 600 1000 1000 1500 2000Twin 300 500 600 1000 1000 1500 2000- 200 200 200 200 200 200 200Z Axis maximum travel (mm) - 500 500 1000 1000 1000 1000 1000Y Axis maximum travel(mm)- 400 400 400 400 400 400 400Component rotation (rpm) - 0.05 5 0.05 5 0.05 5 0.03 3 0.03 3 0.02 2 0.01 1Wire speeds (m/min) - 0.2 15 - Available on all roll claddersWire sizes - 1.0, 1.2, 1.6, 2.0, 2.4, 2.8, 3.2, 4.0, 4.5, 5.0 - Available on all roll claddersWelding ProcessesOpen - Yes Yes Yes Yes Yes Yes YesGas - Yes Yes Yes Yes Yes Yes YesSubmerged - Yes Yes Yes Yes Yes Yes Yes

Machines Under The Spotlight1Wire Feeder (remotely controllable viaD3-Touch)• Quick release feed gears• Integral wire straightening unit• Adjustable feed gear tensioning• Lightweight cast aluminium body• Ability to feed single & twin wire2Spindle Module• Controls surface speed• Auto Diameter adjustment• Step angle control (forward andbackward)• Alternate movement3Quick lock grip (Chuck-jaws)• Safely secures & clamps rolls ona suspension mounted linear slideway system• Self centringSoftware features:Data Logger• Logs welding conditionsSequence Programmer• Saves machine parameters for weldingcomplete components• Welding repeatability84256All MultiSurfacer TM machines have been fitted with the latest health andsafety features. The technical features have been upgraded for maximumperformance and achieve outstanding component reproducibility and qualitytime after time.1171031911Clamping System• Pneumatic clamping system• Easy operation• Provides constant linearpressure to the roll up to theweight of the roll• Precise control of clampingforce• Self centring of clamp forroll thermal expansion andcontraction10Cable management• Features an energy chainmanagement system• Safely incorporates all cableswithin one assembly• Ensures loose cables don’taffect moving parts of themachine• Reduces noise interference4Pendant Control• Jogs X, Z, Wirefeed, Spindle andOscillator axes• Emergency stop button• Start & Stop weld• Controls Spindle & Oscillator functionsFlux recovery system featuring:• Vacuum pump• Hopper• Separating conveyor• Air filter• Self-circulating recoverysystem• Flux preheat95678Fume Extraction & Filter Box• Safely extracts welding fumesdirectly from the welding head• Modular aluminium ducting• Semi-automatic filter cleaningMilling Unit• Provides a rough machiningprocess to clad rolls• Machines roll during finalweld passLinear slide ways• For smooth and trouble freeoperation of X-Z carriagesOscillator• Fitted to provide smoothlinear travel of weld headresulting in a precision welddeposit8 9 Automated Roll Cladding Technology

Machines Under The SpotlightWirefeeder angle unit andposition adjusterBeta Angle GearboxBeta HandleY Axis HandleAlpha HandleAlpha Angle GearboxOscillatorβY Y 2αWelding ProcessesFlexibility is a key feature in the MultiSurfacer TM range of machines.All MultiSurfacer TM machines are adaptable to operate with open arc,submerged arc or gas shielded welding processes. These machinescan be used with single of multiple heads and operate with single ortwin wire for maximum productivity.Submerged Arc WeldingBest suited for large diameter rolls which require higher welddeposition rates. Automatic flux recovery is designed to recirculatethe flux back through a series of filters into the weld reducing wasteand flux replenishment time.Submerged arc weldingOpen Arc WeldingAngleometerOpen arc welding technology is normally applicable to claddingcontinuous casting rolls and small diameter rolls.WirefeederGas Shielded WeldingWA Flux recovery and slagseparationWeld Head Heat ShieldGas shielded welding is applied when a high quality defect free weld is required. Bearing areas ofrolls are commonly clad with shielded processes.Additional product features providing added health & safety protection in a welding environment areavailable, these are as follows:• Protective shields - Protects the operator from the welding arc and offers protective viewingLike all the other aspects of our roll cladding machines,the wire feeders and welding guns perform in unison withthe highest quality wire feeder angle unit and positionadjuster.General features include:• Accurate welding gun angle position in two axes (α and β axis)• Top dead centre adjustment• Fully sealed heavy duty oscillatorWire Feeder features:• Universally suitable for flux-cored and solid wire• Heavy duty and robust design• Quick set-up• True wire speed monitoring and feedback• Ease in reproducibility in wire tension adjustment• End of wire sensorWater Cooled Welding GunWA Universal Tip AdapterFull Range of WA Welding Tips• Fume Extraction - Safely extracts welding fumes from the weld headTechnical SupportWA EngineeringThe engineering department at Welding Alloys utilises the latest in mechanical, electrical and softwarecapabilities in order to deliver a comprehensive welding solution. We undertake thorough analysis ofour customers’ needs, both visible and hidden, to provide a machine designed for the customer, withthe customer.WA TrainingIn addition to delivering a welding solution, WA are able to provide optional multi-level training tooperators and managers alike from our dedicated team of application specialists.WA ReliabilityAt WA we know the importance of reliable machines and appreciate how expensive machinedowntime can be. We provide a variety of maintenance and upgrade packages to maximiseproductivity, reduce operating costs and extend the overall operations lifespan of our production line.Each machine which leaves WA is covered by our guarantee, giving you the confidence in knowingwe provide a quality product which meets the specified needs of your production.10 11 Automated Roll Cladding Technology

A perfectly controlled technologyWA Cored Wire TMDesign and manufacture alltypes of cored welding wiresWA MultiSurfacer TMDesign and manufactureof automated weldingequipment for hardfacing andrebuilding applicationsWA Integra TM ServicesInnovative hardfacing andrebuilding solutions byweldingA worldwide presenceUnited Kingdom (Head Office)Welding Alloys LtdArgentinaWelding Alloys Argentina S.A.Australia (Trading Partner)Specialised Welding Products Pty LtdBrazilWelding Alloys Brazil LtdaChinaWelding Alloys China LtdEgyptWelding Alloys EgyptFinlandWelding Alloys Finland OyFranceWelding Alloys France SASGermanyWelding Alloys Deutschland GmbHGreeceWelding Alloys Hellas EPEIndiaWelding Alloys South Asia Pvt LtdItalyWelding Alloys Italiana s.r.l.JapanWelding Alloys JapanMalaysiaWelding Alloys (Far East) Sdn. Bhd.MexicoWelding Alloys Panamericana S.A. de C.V.MoroccoWelding Alloys Maroc SàrlPolandWelding Alloys Polska Sp. z o.o.RussiaZAO Welding AlloysSouth AfricaWASA (PTY) LtdSouth KoreaWelding Alloys Korea LtdSpainWelding Alloys EspañaSwedenWelding Alloys SwedenTaiwanWelding Alloys Taiwan Co.ThailandWelding Alloys (Thailand) Co. LtdTurkeyWelding Alloys Limited ŞirketiUkraineWelding Alloys UkraineUnited Arab EmiratesWelding Alloys Middle East FZCUSAWelding Alloys (USA) Inc.VietnamWelding Alloys Vietnam Co. Ltdwww.welding-alloys.comWelding Alloys Group 2012. WA Cored Wire, WA Integra, WA MultiSurfacer, Hardlite, Tuffplate, and 3-DCarb trade and registered marks and logos are the property of the Welding Alloys Group. v1.0