Casting Repair
Casting Repair
(OP)
I have a boom (about 6 foot long) that is made IAW ASTM-A27,A148 Class 150-125 chemical composition is equivalent to 4130 Except Si is .64%, and is furnish in an “as cast” condition.
Due to misuse the lower part of the boom is wearing to a point that there is some concern it will not carry the required load. I have been working on a repair procedure, but since I am not familiar with cast repair I’m a little hesitant to recommend something.
What I am considering is removing (by machining) the worn part and manufacturing a new piece to replace it and then weld it in place. This new piece is basically a 3”dia by 6” long cylinder that will be 'fitted' into the end of the boom.
Is there any detailed information available, mainly on the welding design, how much? Or are there any companies that can do this repair?
There is also a track the attaches to the end of the boom that needs to be repaired as well. Same material, a little different repaired needed.
Thanks in advance.
Due to misuse the lower part of the boom is wearing to a point that there is some concern it will not carry the required load. I have been working on a repair procedure, but since I am not familiar with cast repair I’m a little hesitant to recommend something.
What I am considering is removing (by machining) the worn part and manufacturing a new piece to replace it and then weld it in place. This new piece is basically a 3”dia by 6” long cylinder that will be 'fitted' into the end of the boom.
Is there any detailed information available, mainly on the welding design, how much? Or are there any companies that can do this repair?
There is also a track the attaches to the end of the boom that needs to be repaired as well. Same material, a little different repaired needed.
Thanks in advance.





RE: Casting Repair
I would start searching for a Metallurgical/Welding laboratory or consultants in your region. Describe the problem to them. They should send a field engineer out to evaluate your situation and provide recommendations. Check all references (including having a PE license) and rates before committing to a consultant.
Once a weld repair program is developed it can be properly executed using a competent mechanical repair organization. The key for this repair organization is to have demonstrated welding capability in the form of qualified welding procedures and welders – especially working with mechanical equipment. The welding consultant should be able to help you in this endeavor.
RE: Casting Repair
Depending on how the boom is used and on what equipment it may fall under one of the OSHA/ANSI guidelines and may have to have a authorized repair station or written permission from the OEM to do the work. A competent shop can guide you on this aspect. Agreeing again if there is any hesitancy on anyone’s part then get engineering help
Check in your area for a complete shop, welding, machining, old, that works on heavy equipment such as backhoes, front-end loaders, and such. A competent shop can repair most equipment by means such as welding and machining, by machining and installing a steel bushing. Your material is quite common on hydraulic cylinder pivot ends.
RE: Casting Repair
Thanks again....
RE: Casting Repair
RE: Casting Repair
You might have to jump through hoops.
RE: Casting Repair
From what I have been reading it should have been normalized, and I really do not have much faith in the OEM that it was. The operating temps are what you would expect as normal ambient temps, the worse temps being what the Marines are seeing.
I am the “hoops” that are being jumped through…I’m a government Engineer…which is part of the reason I’m trying to get a good understanding on this, so that I can avoid the “hoops.”
RE: Casting Repair
I don't how the repair set up is in today’s armed forces but at one time there were Naval Air Depots, the one that was at Pensacola was "NADEP Pensacola". This group had several competent metallurgical and material people as well as inspection and repair facilities. They would either do the work in house or write the procedures for an approved shop to do the work offsite. They did work for both the Navy and Marines.
There should be some comparable facilities that you could access for assistance.
When the Pensacola group disbanded we hired the head NDT man and the head of the group formed a world class Forensic, Metallurgical, and Materials Engineering Lab. Guess who his best customer is? The Armed forces.
RE: Casting Repair
The microstructure can be determined fairly easily in the field via plactic-tape replication and exam. in an electron microscope. If it really is as-cast, you might be able to normalize it in a large furnace-esp. after any weld repairs.
RE: Casting Repair
RE: Casting Repair
RE: Casting Repair
At the present time I have to do a butt weld with this material on 120mm thick. As a mark for you, I determine that TR800/500 shall be over 7seconds.