Welding Challenge Contest: A World of Challenges

All at sea – a welding challenge in ship propulsion systems

Duplex steel has a greater strength than conventional chrome-nickel steels, and high resistance to corrosion. This is why the Hamilton Jet Global uses this material. The Company with headquarters in Christchurch, New Zealand, is specialized in propulsion systems for ships and associated control systems.

Hamilton Jet uses duplex stainless steel to manufacture wear rings for marine waterjet propulsion systems.  The wear ring protects the impeller race from abrasion. New designs require a joint in this component to be welded. This proved to be a real challenge. Especially because Hamilton has clear requirements on quality: Components are checked for edge notches, distortion and corrosion resistance.

The senior plant and process engineer, Gary Martin, participated in the Contest with this challenge - and won.  Now he has Fronius by his side for finding a solution.

Hard shell, soft core – heat reduction in overlay welding

Overlay welding is frequently used to make parts such as pipe and boring heads last longer in service.  In the process, filler material is applied to a component and forms an additional, protective layer. Hardface Technologies by Postle Industries Inc., based in Cleveland, Ohio USA, develops wires that, by means of overlay welding, form an ideal protective layer.

Pipes that are coated with plastic material on the inside and are made of steel on the outside pose a special challenge. When applying filler material the component cannot be heat to more than about 150 degrees Celsius, otherwise the plastics layer on the inside can sustain damage. Therefore, this needs a special welding solution.

Troy Feuss, sales manager at Hardface Technologies by Postle Industries, submitted this challenge at the SCHWEISSEN & SCHNEIDEN 2017 trade fair in Germany. He is the second of the two winners of the Fronius Welding Challenge Contest.

The Austria Experience

In recent months Troy Feuss and Gary Martin have been working hard with Fronius to solve their challenge. Now it is time for them to get to know the headquarters of Fronius and the country of origin - Austria: Fronius invites the two winners from 4 to 7 November. In addition to technical discussions, a tour through the company, as well as an Austrian cultural program awaits them.

Read more about the challenges and the winners in the new issue of “Perfect Welding. The Magazine.”