 |
|
|
| 001 |
001 |
Repair
of 14 bearing bushes of the gear box, which is destinated
to the bucket wheel drive of an excavator for the field of
open-cast mining. The worn bearing bushes with a diameter
of 280 to 580 mm and a width of 13 to 150 mm were reconstructed
with MM-metal SS-steelceramic and
Hardener yellow. The standstill time of the excavator was
considerable reduced to 72 hours.
|
| 003 |
003 |
The
packing surface of an aluminium mould used for the production
of foamed plastic car seats was repaired by applying MM-metal SS-steelceramic.
The thermal loading is 150 °C, the pressure 10 kg/m2.
|
| 004 |
004 |
5
cracks in the casing of the water pump D-6300/80 at a land
reclamation station was repaired with MM-metal SS-steelceramic and
Hardener yellow.
|
| 005 |
005 |
Repair
of a marine engine with MM-metal SS-steelceramic and
Hardener yellow. Damage: cracked packing surface between
cooling water space and cylinder liner.
|
| 009 |
009 |
|
| 010 |
010 |
|
| 011 |
011 |
Machining
of MM-metal SS-steelceramic with
diamond tools, i.e. Syndite PKD (trademark of “De Beers
Diamond Division”). Data for machining: cutting speed
vc = 60 - 125 m/min; cutting depth ap = 0,5 - 1 mm; feed
f = 0,1 - 0,2 mm/U
|
| 014 |
014 |
Corrosion
damages at a brake drum caused by brake dust were repaired
by using MM-metal SS-steelceramic and
Hardener yellow.
|
| 016 |
016 |
|
| 017 |
017 |
|
| 019 |
019 |
A
worn out bearing bush of a floating dredger was rebuilt using MM-metal SS-steelceramic and
Hardener yellow. Besides MM-metal SS-steel liquid
type with Hardener yellow liquid was injected into a gap
of 4 mm between bearing bush and boom.
|
| 020 |
020 |
Repair
of a paper roll with a diameter appr. 600 mm, length appr.
3400 mm and weight 8000 kg. Cause of damage: undersize of
up to 1 mm at one journal bearing of 270 mm diameter. The
repair has been carried out with MM-metal SS-steelceramic and
Hardener yellow. After curing the roll has been machined
with diamond tools.
|
| 021 |
021 |
|
| 022 |
022 |
Repair
of a frost damage at a centrifugal pump. MM-metal SS-steelceramic together
with Hardener yellow and MM-Fabric-tape (steel) has been
used.
|
| 023 |
023 |
Repairing
of a car engine Mercedes Benz near the crankshaft by using MM-metal SS-steelceramic and
Hardener yellow. For reinforcement a 1 mm steel plate with
the outline of the hole was patched into the engine.
|
| 025 |
025 |
Repair
of four cracks on the cylinder block of a big engine called “Super
MAZ” were repaired with MM-metal SS-steelceramic and
Hardener yellow. One of the cracks passed the oil channel
and was therefore sealed with MM-metal oL-steelceramic and
Hardener red.
|
| 026 |
026 |
|
| 027 |
027 |
Repair
of two tail bearings of a propeller shaft by using MM-metal SS-steelceramic,
Hardener yellow and Hardener green. A ring with exact interior
diameter has been bolted to both sides of the bearing. This
ring has been centralized to the ideal shaft axis. Then MM-metal SS-steelceramic has
been applied and been stretched parallel to the axis.
|
| 028 |
028 |
Repair
of a CV-plant's double cross spray head for the manufacture
of rubber-insulated cable with MM-metal SS-steelceramic and
Hardener yellow.
|
| 029 |
029 |
Repair
of a grinding machine in a cement company. The damage, a
worn out bearing housing, was repaired with MM-metal SS-steelceramic and
Hardener yellow. Herewith the previous repair method “resurfacing
by welding” was replaced.
|
| 030 |
030 |
Repair
of a turbine casing using MM-metal SS-steelceramic and
Hardener yellow. Operating conditions: pressure 4 bar, temperature
150 °C.
|
| 031 |
031 |
A
cylinder head of a car engine having corroded under water
channels was repaired by applying MM-metal SS-steelceramic and
Yellow hardener.
|
| 032 |
032 |
Repairing
of cylinder blocks and working faces of a big marine diesel
engine with MM-metal SS-steelceramic.
The repair was necessary due to damages caused by big abrasion
between cylinder block and working face particularly in the
region of the scaving air receiver. For this type of repair
the engine manufacturer recommends to use exclusively MM-metal SS-steelceramic with
Hardener green.
|
| 034 |
034 |
Repair
of a three-way valve housing for sea water. Material: grey
cast iron. Damage: considerable wash-outs as well as a gaping
hole in the valve housing. The repair was carried out with MM-metal SS-steelceramic and
Hardener yellow and Ceramium,
liquid with Hardener CE.
|
| 036 |
036 |
|
| 037 |
037 |
|
| 055 |
055 |
Repair
of a worn-shaft-bearing for the adjustment of rolls at a
1200 ingot-blooms-rolling stand in a steel rolling mill with MM-metal SS-steelceramic.
By the use of a PolymerMetal instead of a different repair
method the down time was shortened from 75 to 19 hours. This
is equivalent to appr. 7 working shifts. The use of the PolymerMetal MM-metal SS-steel 382,
which has been developed in the meantime, would be recommended
today, which offers even better compressive strength values
for such types of repair. To this repair there is available
an experience report upon request.
|
| 062 |
062 |
The
repair of a crack on the drying drum of a cotton spinning
machine was carried out with MM-metal SS-steelceramic and
Hardener yellow. Data: steam pressure 3 bar, steam temperature
180 - 240 °C.
|
| 084 |
084 |
Repair
of a turbo charger on board of a ship: during a voyage problems
occurred at a turbo charger. The turbine inlet casing was
removed and after cleaning a wasted area of appr. 600 mm
x 130 mm on the lower part of the casing was revealed. Due
to the technical possibilities on board the repair was carried
out with MM-metal SS-steelceramic and
a steel plate as reinforcement. At an exhaust temperature
of appr. 400 °C in this repair area today MultiMetall's VP 10-500 would
have been the better choice.
|
| 092 |
092 |
Sealing
of 3 hydrogen pipings by using MM-metal SS-steelceramic.
Hydrogen was escaping at 350 psi. A metal sleeve with a pressure
compensating valve was prepared. MM-metal SS-steelceramic was
applied to the sleeve and the pipings. While the valve was
open the sleeve was assembled, therefore the hydrogen could
easily escape through the opened valve. After totally curing
of MM-metal SS-steelceramic the
valve was closed and the installation was ready to operate.
If the pipings had been exchanged the whole installation
would have had to be stopped.
|
| 111 |
111 |
Repair
of a water pump. Damage: a crack of approx. 15 cm length.
Data of the pump: year of construction 1969, power: 1500
m3/h, material: GGG-40.3, working pressure 20-40 bar. The
pump has been repaired with MM-metal SS-steelceramic,
Hardener yellow and MM-Fabric tape (carbon). Several attempts
to carry out the repair by conventional welding before failed.
|
| 118 |
118 |
Repair
of the plunger of a metal bar extrusion press using MM-metal SS-steelceramic.
The damage was caused by fatigue fracture. Length of the
plunger 3800 mm, diameter 952 mm, weight 13 to., material:
white cast iron, surface hardness 420 HB, hydraulic pressure
350 bar, operating pressure 2000 to. Procurement of a new
plunger would have cost EUR 81.000 at a delivery time of
appr. 9 months.
|
| 119 |
119 |
|
| 122 |
122 |
|
| 124 |
124 |
Repairing
a corroded and worn out pillow block bedding of a steel sheet
rolling line using MM-metal SS-steelceramic.
The precise pillow block seat was obtained with the help
of a metal plate.
|
| 128 |
128 |
|
| 130 |
130 |
A
cracked housing of a hydraulic
pump in a steering gear made off aluminium was repaired using MM-metal SS-steelceramic with
Hardener yellow. Afterwards the whole housing was coated
with VP 10-017 in
order to seal the pores in the casting.
|
| 134 |
134 |
34
damaged back-up rolls bearing houses of a steel work's hot
strip mill were modified. The above drawing shows a bearing
shell which was damaged by turning of the outer bearing bore.
Conventional repairs of these damages would have been executed
by welding on, heat-treatening and turning to original size.
Cheaper and less time intensive is an innovative repair with MM-metal SS-steelceramic and
Hardener yellow.
|
| 135 |
135 |
34
damaged back-up rolls bearing houses of a steel work's hot
strip mill were modified. The above drawing shows guiding
plates as a fixture to the bearing house. To achieve a constant
distance to the bearing at unchanged plate thickness, the
surface damaged by erosion and mechanical load was restored
by MM-metal SS-steelceramic and
Hardener yellow.
|
| 153 |
153 |
Several
cracks in cylinder no. 1 in the main engine block of a ship
diesel engine, which probably occurred due to aging and vibration,
have been closed with MM-metal SS-steelceramic and
Hardener yellow. The cylinder jacket had long vertical cracks
of 215 mm and 125 mm length and two further cracks of 135
mm each in the upper area. Even 7 years after the repair
has been carried out, the repaired ship engine is in operation
without complaints. The extreme difficult repair has been
completed by our Netherlands partner company („EMHA
technisch bureau b.v.“) and company Metalock in a port
in Thailand.
|
| 161 |
161 |
Mistakenly
a hexagon socket screw released and
got in the printing machine of a famous
German printing machine manufacturer. Through this the
screw immediately left an
impression on three pneumatic cylinders (chrome cylinder,
nickel coatings) of the
arrangement. First the screw impressions were grinded
and cleaned with acetone and the
surfaces to be filled were roughened. Then by means of
spatula MM-metal SS-steelceramic was
applied, surplus material drawn off and approx. 2 hours
later grinded. This process was
repeated until the measure corresponded to the measure
of the cylinder taking into account a
tolerance of 0,005 mm. Finally the repair place was reconditioned
/ polished. The result were
clean passages come along with a clean print image.
|
|
|
|
|
|
| - |
- |
-
|
|
|
|
|
|
| 055 |
055 |
Repair
of a worn-shaft-bearing for the adjustment of rolls at a
1200 ingot-blooms-rolling stand in a steel rolling mill with MM-metal SS-steelceramic.
By the use of a PolymerMetal instead of a different repair
method the down time was shortened from 75 to 19 hours. This
is equivalent to appr. 7 working shifts. The use of the PolymerMetal MM-metal SS-steel 382,
which has been developed in the meantime, would be recommended
today, which offers even better compressive strength values
for such types of repair. To this repair there is available
an experience report upon request.
|
| 139 |
139 |
After
many years of working, the worn-out rock shaft of a crushing
plant for recycling demolition material was repaired with MM-metal SS-steel 382 in
September 2002. First the driving fly wheel was carefully dismantled
to receive access to the shaft. After the surface preparation
of the up to 1 mm worn-out shaft area, MM-metal SS-steel 382 was
applied and then machined down to the desired diameter. A replacement
due to the necessary dismantling of the damaged shaft, the
purchase and the assembly of a new shaft, would have involved
considerable additional costs and time. An examination 4,5
years later (March 2007) has come to the result, that the repaired
work piece is still in function without any complaints. |
| 152 |
152 |
Onto
a damaged area of an axle end MM-metal SS-steel,
later MM-metal SS-steel 382 was
applied to receive a higher surface quality. After curing,
the work piece was machined down with a lathe to the desired
diameter.
|
|
|
|
|
|
| 019 |
019 |
A
worn out bearing bush of a floating dredger was rebuilt using MM-metal SS-steelceramic and
Hardener yellow. Besides MM-metal SS-steel liquid
type with Hardener yellow liquid was injected into a gap
of 4 mm between bearing bush and boom.
|
| 033 |
033 |
The
seat of a ball bearing of a shaft, which serves for lining
up, showed an abrasion of 0,2 mm. First the seat of the ball
was turned off by 0,5 mm, then the repair site was cleaned
with MM-Degreaser Z. Afterwards MM-metal SS-steel with
Hardener yellow was applied. Finally the original shaft diameter
was reached again by machining. Now the shaft was operational
again without any problems.
|
| 040 |
040 |
During
the maintenance on a fuel/oil storage tank several leakages
were noticed. After sandblasting the leakages were sealed
by using the Direct MM-Bonding method with MM-metal oL-steelceramic and
Hardener red. Furthermore parts affected by pitting were
coated by applying MM-metal SS-steel,
pasty. 24 hours were needed for the repair works with PolymerMetals,
curing time included. The usual repair procedure including
emptying of the tanks, cleaning of steel walls and welding
would have taken 6 days.
|
| 049 |
049 |
Through
leakages at the sealing surface of a cylinder liner's engine
block cooling water flew out. The reconstruction work was
affected with MM-metal SS-steel and
Hardener yellow at eight cylinder block threads. After the
application procedure the seats were machined to nominal
diameter 308 mm. The main engine was an engine Daihatsu type
8 DSM 26, power 1252 kW, 720 U/min.
|
| 099 |
099 |
A
leakage in a 154 KV P.O.F. insulation pipe was sealed using MM-metal oL-steelceramic and
Hardener red working with the Direct-MM-Bonding method. In
addition corrosion damages of the piping were removed by
applying MM-metal SS-steel,
liquid and Hardener yellow, liquid. Oil pressure 200 psi,
diameter of the piping 300 mm, oil quality polybdenum.
|
| 125 |
125 |
Repair
of two-stroke engine cylinder liners Sulzer RND 76N ship's
diesel engine with MM-metal SS-steel and
Hardener yellow. The outer diameter is 900 mm and the inner
diameter is 760 mm.
|
| 127 |
127 |
Repair
of a car's cooling water circulating pump with MM-metal SS-steel,
liquid and Hardener yellow, liquid.
|
| 140 |
140 |
In
a steel plant the repair of a broken spool reductor with
a weight of 40 t would have taken up 10 days by using the
conventional way of welding. By using the repair technology
of MultiMetall combined with the PolymerMetal MM-metal SS-steel and
MM-Release agent a repair time of just 27 hours was necessary.
At the spool reductor a stress of 120 MPa occurs.
|
| 141 |
141 |
A
damaged injection mould for manufacturing plastic cups at
a refuse dressing plant was repaired with MM-metal SS-steel.
|
| 145 |
145 |
A
reeling machine was worn out due to abrasion. After roughening
the surface to be treated, it was coated with the PolymerMetal MM-metal SS-steel and
therefore put into working order again.
|
| 147 |
147 |
In
a mining plant the cost and time intensive new acquisition
of a replacement shaft for a damaged shaft of a vibrating
screen was prevented by the repair with MM-metal SS-steel.
|
| 149 |
149 |
Due
to abrasion a worn out metal ring of a dredging pump had
to be replaced. With the help of MM-metal SS-steel the
new metal ring was fixed. PolymerMetals present a high shearing
strength; MM-metal SS-steel offers
a value 30 MPa.
|
| 150 |
150 |
A
broken pump casing was repaired with the help of the PolymerMetal MM-metal SS-steel.
|
| 151 |
151 |
Into
an old cracked valve with a broken flange, a pipe with a
suitable diameter was inserted and fixed by using the PolymerMetal MM-metal SS-steel.
Then this connection was secured by several screws.
|
| 152 |
152 |
Onto
a damaged area of an axle end MM-metal SS-steel,
later MM-metal SS-steel 382 was
applied to receive a higher surface quality. After curing,
the work piece was machined down with a lathe to the desired
diameter.
|
|
|
|
|
|
| 008 |
008 |
|
| 018 |
018 |
|
| 024 |
024 |
|
| 025 |
025 |
Repair
of four cracks on the cylinder block of a big engine called “Super
MAZ” were repaired with MM-metal SS-steelceramic and
Hardener yellow. One of the cracks passed the oil channel
and was therefore sealed with MM-metal oL-steelceramic and
Hardener red.
|
| 038 |
038 |
During
the first run of a diesel locomotive's engine a shrinkage
cavity in the casting was found above the engine block near
the central lubrication. Oil was leaking from this cavity.
The repair was carried out with MM-metal oL-steelceramic and
Hardener yellow. After several test runs the repaired engine
has been installed into a new diesel locomotive.
|
| 039 |
039 |
Oil
flew trough a crack at the cable terminal funnel of a block
transformer. The repair was carried out by the method of
Direct-MM-Bonding with MM-metal oL-steelceramic,
Hardener red and Hardener yellow.
|
| 040 |
040 |
During
the maintenance on a fuel/oil storage tank several leakages
were noticed. After sandblasting the leakages were sealed
by using the Direct MM-Bonding method with MM-metal oL-steelceramic and
Hardener red. Furthermore parts affected by pitting were
coated by applying MM-metal SS-steel,
pasty. 24 hours were needed for the repair works with PolymerMetals,
curing time included. The usual repair procedure including
emptying of the tanks, cleaning of steel walls and welding
would have taken 6 days.
|
| 041 |
041 |
Sealing
of a large transformer in a power station. The leakage was
sealed with MM-metal oL-steelceramic and
Hardener red using the Direct-MM-Bonding method. Then a layer
of MM-metal oL-steelceramic and
Hardener yellow was applied to the first layer.
|
| 042 |
042 |
The
surface of a transformer between copper plates and fibreglass
coating showed several oil leakages. The repair has been
affected using the Direct-MM-Bonding method with MM-metal oL-steelceramic combined
with Hardener red and Hardener yellow afterwards.
|
| 043 |
043 |
In
a transformer station plant oil leakages at welding seams
of a conservator were repaired with the Direct-MM-Bonding
method by using MM-metal oL-steelceramic,
Hardener red and Hardener yellow.
|
| 044 |
044 |
At
the on-load tap changer of a large transformer oil was penetrating
through cracks between the top and the on-load tap-changing
equipment. The Direct-MM-Bonding method was used to solve
this repair problem. It was carried out with MM-metal oL-steelceramic and
Hardener red and afterwards Hardener yellow.
|
| 045 |
045 |
In
order to avoid oil leakages at current transformers, the
bolts were inserted with MM-metal oL-steelceramic and
Hardener yellow.
|
| 047 |
047 |
|
| 079 |
079 |
|
| 088 |
088 |
A
machine casing was repaired by using MM-metal oL-steelceramic and
Hardener red and afterwards Hardener yellow. The application
has been done using the Direct-MM-Bonding technology.
|
| 099 |
099 |
A
leakage in a 154 KV P.O.F. insulation pipe was sealed using MM-metal oL-steelceramic and
Hardener red working with the Direct-MM-Bonding method. In
addition corrosion damages of the piping were removed by
applying MM-metal SS-steel,
liquid and Hardener yellow, liquid. Oil pressure 200 psi,
diameter of the piping 300 mm, oil quality polybdenum.
|
| 109 |
109 |
Repair
of a hair crack at a main engine block of a bulldozer (make
Komatsu). The hair crack was appr. 20 inches long. A first
attempt to repair by electro welding failed. Then the engine
block was successfully restored by using the Direct-MM-Bonding
method with MM-metal oL-steelceramic.
|
| 110 |
110 |
|
| 114 |
114 |
|
| 115 |
115 |
Repair
of a leaking simplex compact packing. The repair was difficult
due to oil pouring out of the repair site. Therefore it was
decided to use the Direct-MM-Bonding method by applying the
PolymerMetal directly on the greasy surface. Here MM-metal oL-steelceramic with
Hardener red was chosen.
|
| 116 |
116 |
|
| 137 |
137 |
Due
to steady climate influence (salty air and rainfall) several
strong corroded areas and a leakage of a natural gas carrying
pipe system on an oil platform have been repaired with MM-metal oL-steelceramic.
To avoid any extra costs the repair was carried out without
switching off the system and so the repair has been done
at a pressure of 10 bar. Gas streamed out of a leakage of
a 10 inch, therefore a provisional valve was built, through
which the gas was able to stream out until the final closure
of the leakage. A construction consisting of a plate and
a nut was made, which was then fixed on the leaky place of
the pipe by using MM-metal oL-steelceramic.
After the PolymerMetal was cured this valve was closed by
using a screw. Finally a coating of MM-metal oL-steelceramic was
applied over the complete provisional construction for safety
reasons.
|
| 154 |
154 |
Oil
exuded through micro cracks caused by vibration in a defective
welded seam. The leak of oil has amplified after unsuccessful
attempt to execute repair by usual welding. Then it was decided
to carry out a repair by using the “Direct-MM-Bonding”-
technology with the help of MM-metal oL-steelceramic and
hardener red followed by a second layer of MM-metal oL-steelceramic with
hardener yellow.
|
| 155 |
155 |
Repair
of a vertical crack in a welding in length of ~ 80 mm by
using the repair technology “Direct-MM-Bonding” with
the help of MM-metal oL-steelceramic and
the hardeners red and yellow.
|
| 156 |
156 |
The
welding at 19 places of transformers had micro cracks and
blowholes, where oil exuded. First the paint has been removed
with an electro drill equipped with an abrasive tool and
the metal has been cleaned at the defective areas. Then MM-metal oL-steelceramic with
Hardener red and afterwards Hardener yellow was applied.
After checking the tightness of the repaired areas the corresponding
areas have been painted over again.
|
| 157 |
157 |
Elimination
of a leak of oil in a welding using the PolymerMetal MM-metal oL-steelceramic with
Hardener red and Hardener yellow.
|
| 158 |
158 |
Several
worn areas of a steel plant’s leaky power transformer
have been sealed with MM-metal oL-steelceramic and
Hardener yellow.
|
| 159 |
159 |
A damaged
power transformer located in a steel plant has been repaired
by using MM-metal oL-steelceramic and
Hardener yellow.
|
|
|
|
|
|
| 015 |
015 |
Sealing
of a steam pipe under pressure using MM-metal UW while
the plant was still operating with a pressure of 87 psi at
a temperature of 160 °C.
|
| 046 |
046 |
Sealing
of a cooling water pipe made of steel without switching off
the plant. Cause of the damage was material fatigue. The
repair was carried out with MM-metal UW with
Hardener UW3 and MM-Fabric tape (glass fibre).
|
| 050 |
050 |
Sealing
of an overrun container on board of a ship with MM-metal UW and
Hardener UW3 respectively Hardener UW9.
|
| 051 |
051 |
Repair
of a water piping which was under pressure by using MM-metal UW and
Hardener UW3. The sealing has been carried out while water
was still escaping.
|
| 052 |
052 |
Sealing
of a warm water pipe in a heat station with MM-metal UW and
Hardener UW9 together with MM-Fabric tape.
|
| 053 |
053 |
Leakage
removal at a hydraulic pressure header tank with MM-metal UW and
Hardener UW3.
|
| 054 |
054 |
A
leakage in a cooling pipe was sealed without reducing the
water pressure. The repair was carried out with MM-metal UW and
Hardener UW9.
|
| 056 |
056 |
Sealing
of a steam pipe under pressure by using MM-metal UW and
Hardener UW3. Reason for the repair were cracks of welding
seams caused by vibration at a working pressure of 2 bar
and a temperature of 90 °C.
|
| 058 |
058 |
Repair
of a valve at an installation pipe with MM-metal UW and
Hardener UW3. The leakages have been caused by corrosion
due to water and sand.
|
| 059 |
059 |
Sealing
of a cooling water pipe in the high-hazard area of a high-pressure
water installation without interrupting operation. The leakage
was a 5 cm long crack at a water pressure of 2,5 bar. The
sealing was carried out with MM-metal UW and
Hardener UW3 without pressure reduction. Materials used were
a pre-shaped metal sheeting and MM-Fabric tape (glass fibre).
|
| 060 |
060 |
A
tanker (size 15.000 GRT) loaded with petrol, touched ground.
Damage was an extensive leakage with a size of 200 mm x 700
mm. The repair was carried out under water using MM-metal UW with
Hardener UW9 and a metal plate.
|
| 061 |
061 |
A
leakage at the stern of a barge was sealed under water using MM-metal UW with
Hardener UW9. The repair was completed within 30 minutes
time.
|
| 074 |
074 |
Repair
of an oil / gas tank under arctic temperature. The repair
was carried out with MM-metal UW and
Hardener UW3 in Russia.
|
| 078 |
078 |
Repair
of a water piping system which was under pressure using MM-metal UW and
Hardener UW3.
|
| 087 |
087 |
Durable
repair of a leakage in a piping system under water by using MM-metal UW and
Hardener UW9.
|
| 107 |
107 |
A
leaky welding seam of a sea water pump was sealed using MM-metal UW and
Hardener UW9.
|
| 120 |
120 |
Sealing
of a cracked pump casing at reduced water outlet using MM-metal UW and
Hardener UW3.
|
| 123 |
123 |
Repairs
with MM-metal UW and
Hardener UW3 are possible under arctic conditions at temperatures
even down to minus 20 °C.
|
| 133 |
133 |
The
seat of a vessel's pintle bushing has been restored. At first
under water the pintle bushing was fixed at a temperature
of 2-3 °C. Then MM-metal UW with
Hardener UW9 was injected through several threaded ports
drilled into the bushing flange. Here an appr. 1,4 mm clearance
between pintle bushing and gudgeon casting filled. The repair
was carried out by a Canadian diving company. Because of
the quick total curing time of the PolymerMetal in spite
of the low temperature the vessel was ready for action again
within short time.
|
|
|
|
|
|
| 006 |
006 |
Repair
of several bilge pumps and fire pumps (type Loew VZLG 65/1/2,
power 60 m3/h) with Ceramium pasty
and Ceramium liquid.
An inspection 3 years after the repair did not show any faults
or objections at the repaired object.
|
| 007 |
007 |
Repair
of heat exchangers using Ceramium and
Hardener CE.
|
| 012 |
012 |
Elimination
of damages at two vessel's propeller caused by cavitation
with Ceramium and
Hardener CE.
|
| 013 |
013 |
Deep
groves at the surface were filled out with Ceramium and
Hardener CE.
|
| 034 |
034 |
Repair
of a three-way valve housing for sea water. Material: grey
cast iron. Damage: considerable wash-outs as well as a gaping
hole in the valve housing. The repair was carried out with MM-metal SS-steelceramic and
Hardener yellow and Ceramium,
liquid with Hardener CE.
|
| 035 |
035 |
The
upper part of an impeller of a pump for filling up the ready
cement in sacks was exposed to very strong wear and tear.
In the meantime it was tried to restore by build-up welding.
The final repair has been carried out with Ceramium and
Hardener CE.
|
| 048 |
048 |
Repair
of an automatic glass machine at a channel for broken glass
and water. The coating procedure was affected in two steps
- first application with Ceramium,
pasty, followed by a second application with Ceramium,
liquid. The previous reconstruction procedure was build-up
welding.
|
| 057 |
057 |
Repair
of a corroded gas pipe due to throat gas from blast furnace
carried out with Ceramium and
Hardener CE.
|
| 063 |
063 |
Reconstruction
of the sealing surface of the cover at a turbine. The repair
was carried out with Ceramium,
liquid and Hardener CE at an electric generating station.
|
| 064 |
064 |
A
crack at an enamel coated chemical plant for the production
of solvents was filled with Ceramium and
Hardener CE.
|
| 065 |
065 |
Ceramium with
hardener CE was used to repair cracks and damages caused
by erosion between cast segments at a gas washer (Venturi)
of a blast furnace cleaning facility. Due to this the life
of the device was doubled.
|
| 066 |
066 |
Repair
of two turbine rotors. Damages were present at all areas
of the blades where the water leaves the blades. First large
holes have been welded. Then the erosive areas have been
filled up with Ceramium,
pasty. Finally a supplementary layer of VP 10-017 has
been applied as protection against cavitation.
|
| 067 |
067 |
Cavitation
damages on a flange were repaired by using Ceramium pasty
and Hardener CE.
|
| 068 |
068 |
Because
of bad maintenance during the resting period the covers of
3 auxiliary capacitors, each 6 m2 were affected by erosion
of up to 3 cm depth. The volume for filling was obtained
by applying 200 kg Ceramium and
Hardener CE.
|
| 069 |
069 |
Repair
of 160 cylinder liners using Ceramium,
pasty and Hardener CE. Afterwards a layer of Ceramium,
liquid and Hardener CE was applied.
|
| 070 |
070 |
Repair
of a bucket wheel excavator for the field of open-cast mining
by applying Ceramium liquid.
The main drive shaft of the bucket wheel rim, which was damaged
due to abrasion, was reconstructed at a length of 400 mm
with a diameter of 360 mm. The diameter has been reduced
to 350 mm before the rebuilding.
|
| 071 |
071 |
Repair
of the bottom part of a coal mill. The repair has been carried
out both with Ceramium pasty
and Ceramium liquid.
|
| 072 |
072 |
Coating
of the inner respectively outer diameter of a penstock
pipe with diameter appr. 1,5 m , length appr. 900 m. Damages
were caused by erosion and abrasion due to water and sand.
The coating was affected with Ceramium pasty
with Hardener CE.
|
| 073 |
073 |
Repair
of a Kort nozzle using Ceramium with
Hardener CE.
|
| 075 |
075 |
Elimination
of cavitation damages at a bronze propeller and a steel propeller
with Ceramium and
Hardener CE.
|
| 083 |
083 |
Repair
of heat exchangers using Ceramium and
Hardener CE.
|
| 089 |
089 |
Repair
of the soot blower compressor at a heat station by coating
the additional cooler with Ceramium.
The coating was affected in two steps: a first application
of Ceramium pasty
type, afterwards a second application with Ceramium liquid
type.
|
| 090 |
090 |
A cover
with Ceramium was
reconstructed. The coating was affected in two working
procedures: First a surface reconstruction with Ceramium,
pasty and Hardener CE. Second an application with Ceramium,
liquid with Hardener CE.
|
| 093 |
093 |
Repair
of a ship propeller shaft made of bronze in the zone of
the stuffing box packing with Ceramium pasty
and Hardener CE. The original shaft diameter of 630 mm
was machined down to 615 mm over a length of 60 cm. After
the application of Ceramium the
diameter was 632 mm. Finally the applied Ceramium was
turned down to the requested diameter. For the complete
repair 39 units of Ceramium /
Hardener CE were used for applying 4 layers. Additionally
3 layers of glass fibre fabric tape were processed.
|
| 094 |
094 |
Blocking
valves have been reconstructed by using Ceramium.
Responsible was serious wear and tear on the steel alloy
caused by the clay loam.
|
| 095 |
095 |
Repair
of an undersized bronze propeller shaft: diameter appr. 380
mm, length appr. 6000 mm due to friction in the stuffing
box. Material used: Ceramium with
Hardener CE. After curing the propeller shaft was machined.
|
| 096 |
096 |
Repair
of a propeller shaft near the stuffing box packing by using Ceramium pasty
with Hardener CE.
|
| 097 |
097 |
Maintenance
of a shaft of a paint coating machine at a paper mill in
the zone of the stuffing box packing with Ceramium pasty
and Hardener CE. The formerly common company repair solution
by metal spraying was not considered because the machine
would have been too long out of order.
|
| 104 |
104 |
An
additional water-centrifugal pump being damaged by erosion
and cavitation was rebuilt using Ceramium.
Housing and flanged socket were coated inside with VP 10-017.
|
| 105 |
105 |
Coating
of a turbine impeller due to cavitation damages. Here the
materials Ceramium and
Hardener CE were used.
|
| 108 |
108 |
Repair
of worn piston rods caused by the exhausts of a blast furnace.
The piston rods were brought to nominal diameter again using Ceramium.
After the repair has been completed the piston rods are in
operation again for 3 years.
|
| 112 |
112 |
Corrosion
and abrasion damages on high pressure fan casings in a paper-mill
have been removed using Ceramium pasty
and Hardener CE.
|
| 113 |
113 |
Repair
of gas drilling surge valves. Abrasion due to escaping gas
(2800 psi) and carrying contaminations such as e.g. sand.
The repair has been carried out using Ceramium.
A later inspection did not reveal any damages.
|
| 117 |
117 |
A
damaged shaft of a conveyer worm was rebuilt using Ceramium.
An inspection after 6 months did not reveal any damages on
the conveyer worm.
|
| 126 |
126 |
Repair
of a pump housing. Damage: erosion and corrosion had reduced
the wall thickness to a minimum. The resulting damage was
a hole in the housing. For deep wash-outs Ceramium,
pasty with MM-Fabric mats (steel) were used. For the purpose
of wear-and-tear resistance the pump was coated with Ceramium,
liquid.
|
| 129 |
129 |
Durable
protection against wear and corrosion on welded constructions
i.e. receivers and covers can be achieved by using Ceramium together
with an application of VP 10-017 afterwards.
|
| 132 |
132 |
In
a granulation plant several pumps (2 granulation pumps, 2
condense pumps, 2 cooling circuit pumps, 1 submerged pump)
material loss caused by wear. All pump casings and running
wheels consist of hard cast. Pumping medium is circuit water
with a slag sand content of appr. 10 mg/l at a average corn
size of 0,3 mm. The water temperature is 90 °C (194 °F)
at the cooling circuit pumps and 40 °C (104 °F) at
the condense pumps. The pumps have been repaired with a coating
of Ceramium.
|
| 136 |
136 |
A
worn pump casing was coated with Ceramium liquid
for demonstration purposes. Depending on the application
consistency, Ceramium can
be applied with a brush, a spatula or any other suitable
tool or by pouring or injecting. Before coating, the surface
must be roughened i.e. by sand blasting and then cleaned
with MM-Degreaser Z or Acetone.
|
| 143 |
143 |
Several
valves of a line system on an oil platform were damaged.
The problem was abrasion caused by the transportation of
sand and sea water. The damages were repaired with the help
of Ceramium,
pasty.
|
| 144 |
144 |
In
a power plant a turbine paddle was worn out due to water.
The pasty variant of the PolymerMetal Ceramium was
used to rebuild the worn-out areas.
|
| 146 |
146 |
At
a steelwork, heavy erosion caused damage of a blast furnace.
Several areas of the conveyer cone were severely damaged
due to the continuous loading with coke. Some plates were
welded on the cone and then coated with Ceramium as
well as some other damaged parts and the machine was put
into operation successfully again.
|
| 148 |
148 |
Several
holes and damaged spots respectively in the roof of a big
tank at an oil refinery were first coated with Ceramium.
Then a layer of MM-Elastomer was
applied to compensate any bigger tensions.
|
| 166 |
166 |
The
turbine in an important hydroelectric power plant in South
America was repaired with Ceramium. A turbine shovel was
damaged by effect of cavitation and erosion. In the turbine
wheel there is a pressure of up to 12 bar and 700.000 litres
water per second is moved. After 10 months of continuous
operation a revision was carried out and merely low erosion
and cavitation damages could be determined in the Ceramium coating which were not of further importance. 95% of the
Ceramium coating was in good order.
|
| 167 |
167 |
In
November 2009 five at about 100 year-old locks were adapted
to the operational and traffic-technical demands for the
next years as a result of basic repair measures respectively
steel hydraulics constructions improvements along the Dortmund-Ems
canal. The concerned lock gates (lifting gates) are circumferentially
furnished with trapezoid-shaped elastic lips. After having
been moved up and bordering to the corresponding counter
surfaces (gate seats) the lifting gate should close tightly.
In the course of the time these gate seats showed pittings
and they were no longer sufficient planar. Therefore the
pasty version of the PolymerCeramic Ceramium was chosen
to balance these areas. Per gate a seat area of about 20
running
metres of 7 cm width with an average coating thickness
up to 7 mm Ceramium was calculated. Because of the low
ambient
(10 °C) and work piece temperature at that season and
the weather dependence the repair and curing conditions
were difficult. Nevertheless after the repair the responsible
water and shipping authority could release the locks respectively
the canal again for the shipping according to plan.
|
|
|
|
|
|
| - |
- |
-
|
|
|
|
|
|
| 160 |
160 |
A
damaged trommel screen for the production of non-woven fabric
has been repaired
with
Ceramium BD and Sealium. One wave segment of the wave structure
consisting of Nickel
was broken out. The new wavelike bridges had to be inserted
suitable to the existing bridges,
so that the fabric won’t stuck in places at the later
operation of the trommel screen. After
previous grinding with rough sandpaper, and the bonding of
prepared waves by using
Ceramium BD, surplus adhesive material was removed. The outlines
were grinded again and
the outlets bored up again carefully. Finally the repair
area was sealed with Sealium. After
bringing into service again the repair area resisted the
high continual water pressure of 170
bar permanently.
|
| 162 |
162 |
In
a nickel drum which is used for the coinage of patterns
on fleece materials cracks and
fractures places were detected. The fractured places
of the very thin-walled (2 mm) drum had
to be stabilised. Without a repair there was a danger
of fleece material getting stuck in the
drum causing further damages. First the damaged areas
have been grinded and smooth
hollow-shaped passages have been created. After roughening
and cleaning with acetone
Ceramium BD was applied on the areas and cracks and fractures
were filled. Those places
were grinded again, adapted and the outlines were milled.
Afterwards the surface was coated
with Sealium. After end of the repair works the trommel
screen could be successfully put into
operation again under the usual operation conditions
(working pressure 170 bar).
|
| 163 |
163 |
A
tool form of nickel for the torsos production of complex
medical rubber dummies had to be adapted in the cervical
region. The form was first cut in the cervical area. The
attempt by soldering to join again the parts of the form
being adjusted in the meantime, failed. Leakages by embedded
air bubbles occurred in the cast parts in the area of the
seam. By the alternative application of Ceramium BD the
form could be put into operation again successfully. The
seam was grinded 2 mm deep, cleaned with acetone and warmed
up in the stove on 100 °C. Then Ceramium BD was
applied in the repair area. After sufficient curing of approx.
1 - 1,5 hours the form was grinded and covered with Sealium respectively
immersed in Sealium. The
result was a clean surface without noticeable passages in
the seam. The form stood firm easily the working temperature
of 265 °C.
|
|
|
|
|
|
| 066 |
066 |
Repair
of two turbine rotors. Damages were present at all areas
of the blades where the water leaves the blades. First
large holes have been welded. Then the erosive areas have
been filled up with Ceramium,
pasty. Finally a supplementary layer of VP 10-017 has
been applied as protection against cavitation.
|
| 086 |
086 |
Various
purposes of VP 10-017,
a viscoplastic polymer-ceramic, which can be applied i.e.
on covers, models, pump housings, mountings, pipe works,
machines and plants. VP 10-017 offers
a durable, elastical, high impact and wear resistant corrosive
protection. VP 10-017 can
be applied with brush or spatula in one go to a application
thickness of 300 µm even on vertical surfaces.
|
| 091 |
091 |
Coatings
with VP 10-017 for
air coolers, tanks and other big surfaces. VP 10-017-coatings
as surface protection and protection against corrosion do
offer a very smooth, flexible and wear resistant surface. VP 10-017 is
temperature resistant up to 100 °C and offers a very
high chemical resistance.
|
| 098 |
098 |
Coating
of a kort nozzle using VP 10-017 as
protection against cavitation and corrosion.
|
| 100 |
100 |
Corrosion
protective coating of ship hatches with VP 10-017.
|
| 104 |
104 |
An
additional water-centrifugal pump being damaged by erosion
and cavitation was rebuilt using Ceramium.
Housing and flanged socket were coated inside with VP 10-017.
|
| 129 |
129 |
Durable
protection against wear and corrosion on welded constructions
i.e. receivers and covers can be achieved by using Ceramium together
with an application of VP 10-017 afterwards.
|
| 130 |
130 |
A
cracked housing of a hydraulic pump in a steering gear made
off aluminium was repaired using MM-metal SS-steelceramic with
Hardener yellow. Afterwards the whole housing was coated
with VP 10-017 in
order to seal the pores in the casting.
|
| 142 |
142 |
Several
defective covers of a heat exchange system were repaired
with VP 10-017.
|
| 164 |
164 |
In
a refinery located in the north of Germany (capacity
~ 4.500.000 tons crude oil per year) a
spindle oil cooler respectively a pipe bundle was coated
at the areas marked red. The facility
with the concerned assembly is used for the crude oil
distillation for the production of benzine
and kerosene. Products like VP 10-017 and further polymer
materials manufactured by
MultiMetall are applied for more than 25 years in the
refinery sector of the respective affiliated
group Texaco/Shell. To this repair there is available
a scale-up of the drawing upon request.
|
|
|
|
|
|
| 102 |
102 |
Repair
of a ship's turbocharger with VP 10-500.
Scourings, cracks and apertures from the gas entrance to
the cooling water side were repaired with VP 10-500.
For the reinforcement two layers of MM-Fabric tape (glass
fibre) were used.
|
| 103 |
103 |
With VP 10-500 a
non-sealant vent plug in a cylinder head at an exhaust port
was repaired. VP 10-500 was
applied in a thickness of appr. 3 mm. Afterwards the plug
seals remained gas-proof in spite of high operating temperatures
of 300 °C.
|
| 122 |
122 |
|
|
|
|
|
|
| 076 |
076 |
A
seized oil pump was repaired by using Molymetall.
|
| 080 |
080 |
Repairing
a damaged bearing bush using Molymetall.
|
| 085 |
085 |
Axial
and radial groves on drilling upright machines and bed ways
were filled with Molymetall and
machined down to size.
|
| 106 |
106 |
A
chrome plated hydraulic piston showed strong surface flaking.
As there were thinnest layers and antifriction properties
required, the repair was affected with Molymetall.
|
| 121 |
121 |
The
bearing seat of a brake shield was reconstructed to its original
size with Molymetall.
First 2 mm were turned down and then Molymetall was
applied. After total curing (appr. 12 h) the size of the
original diameter of the seat was reached by turning down
again.
|
| 131 |
131 |
Due
to ageing and sea water corrosion, the hard chrome coating
in the top section of some hydraulic rams of several vessel
deck hatch covers was peeled off. To avoid re-chroming, the
hydraulic rams were repaired with Molymetall.
First the corroded areas were machined down. Then Molymetall was
applied and after curing machined down to size. The 270 kg
heavy hydraulic cylinders with a diameter of 125 mm work
with a pressure of 280 kg/cm2 and a stroke of 635 mm. Tests,
carried out 5 years after the repair, show that the hydraulic
rams are still in good condition and fully functional.
|
| 138 |
138 |
The
worn-out shaft of a gear motor for moving an ore conveyer
belt was repaired with PolymerMetal. For this the polymer
material Molymetall was
applied to the damaged shaft on the spot and after partial
curing reduced to the desired dimension by grinding by hand
with abrasive paper. The solution of the problem by using
a PolymerMetal had the big advantage that through this a
dismantling of the facility or shaft was not necessary. Due
to this modern type of repair, the customer was able to save
around 67 hours of machine shut-down.
|
| 165 |
165 |
The
slideways and bedways of 10 elder threading machines for
the processing of drilling rods for the natural gas and oil
industry have been rebuilt with Molymetall by injection/moulding.
The application thickness was partly up to 7 mm. Because
of the high wear resistance, the very low coefficient of
friction and the self-lubricating properties of Molymetall the customer is very satisfied after several previous failed
repairs with competitive products. The machines are in service
again successfully for several years.
|
|
|
|
|
|
| 077 |
077 |
Sealing
of micropores in fittings using Sealium by
immersion or brush method.
|
| 081 |
081 |
Leakages
(micro pores) in a cylinder head were closed with Sealium.
|
| 160 |
160 |
A
damaged trommel screen for the production of non-woven fabric
has been repaired with Ceramium BD and Sealium.
One wave segment of the wave structure consisting of Nickel
was broken out. The new wavelike bridges had to be inserted
suitable to the existing bridges, so that the fabric won’t
stuck in places at the later operation of the trommel screen.
After previous grinding with rough sandpaper, and the bonding
of prepared waves by using Ceramium BD,
surplus adhesive material was removed. The outlines were
grinded again and the outlets bored up again carefully. Finally
the repair area was sealed with Sealium.
After bringing into service again the repair area resisted
the high continual water pressure of 170 bar permanently.
|
| 162 |
162 |
In a
nickel drum which is used for the coinage of patterns on
fleece materials cracks and fractures places were detected.
The fractured places of the very thin-walled (2 mm) drum
had to be stabilised. Without a repair there was a danger
of fleece material getting stuck in the drum causing further
damages. First the damaged areas have been grinded and
smooth hollow-shaped passages have been created. After
roughening and cleaning with acetone Ceramium BD was
applied on the areas and cracks and fractures were filled.
Those places were grinded again, adapted and the outlines
were milled. Afterwards the surface was coated with Sealium.
After end of the repair works the trommel screen could
be successfully put into operation again under the usual
operation conditions (working pressure 170 bar).
|
| 163 |
163 |
A tool
form of nickel for the torsos production of complex medical
rubber dummies had to be
adapted in the cervical region. The form was first cut
in the cervical area. The attempt by
soldering to join again the parts of the form being adjusted
in the meantime, failed. Leakages
by embedded air bubbles occurred in the cast parts in
the area of the seam. By the
alternative application of Ceramium BD the
form could be put into operation again
successfully. The seam was grinded 2 mm deep, cleaned
with acetone and warmed up in the
stove on 100 °C. Then Ceramium BD was applied in the
repair area. After sufficient curing of
approx. 1 - 1,5 hours the form was grinded and covered
with Sealium respectively immersed
in Sealium. The result
was a clean surface without noticeable passages in the
seam. The
form stood firm easily the working temperature of 265 °C.
|
|
|
|
|
|
| 082 |
082 |
|
|
|
|
|
| 002 |
002 |
Sealing
of an oil leak between the cover and diverter switch of a
transformer with MM-Elastomer 95.
First the oil in the transformer was drained and the surface
thoroughly cleaned with MM-Degreaser Z. Finally MM-Elastomer 95
was applied using a brush.
|
| 101 |
101 |
A
conveying belt of a compost filling plant showed a 120 mm
x 130 mm long triangle fracture at the corner. After cleaning
and degreasing with MM-Degreaser Z an application of MM-Elastomer 95
with Hardener EL1 was done. Afterwards the conveying belt
was put into action again with a tensile stress of 5 bar.
|
| 148 |
148 |
Several
holes and damaged spots respectively in the roof of a big
tank at an oil refinery were first coated with Ceramium.
Then a layer of MM-Elastomer was
applied to compensate any bigger tensions.
|
