be_ixf;ym_202106 d_18; ct_50

Laser Cladding And Machining Salvages Slurry Pump Shaft For Mine

ORIGINAL DIMENSIONS RESTORED TO SHAFT

A mining operation suffered a major bearing seizure on the crankpin of a slurry pump shaft. The pump makers approached Goltens to explore the possibility to repair and restore the crankshaft to original diameter in our workshop.

Inspection revealed the crankpin had suffered severe damage resulting in surface hardness levels as high as 397 HB and heat cracks on the pin surface. Goltens offered a solution to machine the pin to undersize but the pump maker required the pin diameter at original specification. To meet the requirement, Goltens proposed an alternative repair solution using laser cladding to rebuild the crankpin diameter and machine it back to original size and tolerance.

  • Damaged slurry pump shaft prior to Goltens repair

    Damaged Journal before machining and cladding

  • Goltens Machinists removing surface cracks before laser cladding

    Removing cracks and hardness before cladding

  • Laser cladding of pump shaft journal at Goltens workshop

    Laser cladding of pre-machined crankpin journal to original diameter

  • Surface of pump journal after Goltens laser cladding

    Laser cladding complete

  • Goltens machining laser cladded journal to original diameter

    Machining journal to original diameter

  • Goltens machine honing pump journal to finish diameter

    Machine honing to finished diameter

  • Goltens using a blueing dummy to check the journal surface after machining

    Blue fitting the journal

  • Sludge pump crankshaft repaired by Goltens

    Sludge pump crankshaft restored to original diameter and specs

  • Goltens laser inspection of slurry pump dimensions with Leica Laser Tracker

    Final inspection with Leica Laser Tracker

  • Goltens 3D report from Leica Laser tracker

    3D Report checking tolerances and alignment

PRE-MACHINING OF CRANKPIN

The crankpin was machined to 2 mm undersize to clear all heat cracks and inspected again by MPI. Once satisfied the cracks and hardness were removed from the surface, the shaft was ready for laser cladding to rebuild the crankpin diameter.

LASER CLADDING

Laser cladding is an efficient way to build up any shaft diameter without inducing high temperature, thus avoiding any kind of distortion or affecting the original metal properties. The process involves a laser beam which creates a molten pool at the workpiece surface, to which the laser coating material is simultaneously added. The result is a layer that is connected with the basic material metallurgically and free of pores and cracks.

The machined crankpin was cladded with 3mm Inconel 625 material. The shaft did not experience any distortion or change in material property. The laser-powder cladding procedure on this shaft material was approved by DNV GL

FINAL MACHINING AND INSPECTION

The crankpin was machined, honed and polished to final size. A precision-machined “bluing” dummy bearing was used to perform blue fitting to ensure good contact surface. Lastly, a portable CMM, Leica Laser Tracker, was used to check and generate a 3-dimensional report indicating the shaft alignment, geometry and tolerances of the crankpin. The customer was fully satisfied with the final outcome and shaft was sent back to the mines for installation.

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