Using the Wearmaster
Make sure the Wearmaster has been mounted from the bottom and is rigid to ensure correct dispensing of tungsten.
It is important the Feed Tube remains relatively straight when welding. Once the tungsten carbide chip enters the Feed tube it is reliant on gravity to drop down into the weld pool. If the Feeder Unit is positioned 1.2 meters above the welding table then the usable table area would be approx. 1 square meter directly underneath the Feeder.
Set flow rate depending on the size of tungsten and the application you are applying it in. 180 to 200grams per minute is the ideal flow rate.
Power is supplied to the system via the flexible voltage system which auto detects 110VAC or 230VAC. The FLOW RATE dial controls the amount of carbide the feeder supplies. The higher the number, the higher the feed rate. A typical setting is somewhere between 4 - 8 Volts.
Set the welder up using the wire manufacturers recommendations for the wire being used.
Attach the torch bracket and dispensing nozzle to the Mig torch/gun. This can be bent to suit your individual torch.
To start dispensing the tungsten depress foot pedal and tungsten will start to flow. Tungsten feeder and Mig welding current must be established at the same time to ensure weld deposit with tungsten embedded in the weld. At the end of the weld release foot pedal and then stop welding current
Please Note: Adjust flow rate accordingly should it be required. Tungsten can only be applied in the down hand welding position.
Tungsten Chip Size
The most common sizes of carbide used would be 14 x 20 mesh or 16 x 20 mesh but of course there are other sizes readily available as well. Talk to your nearest dealer for the correct size for your job.
Carbide Deposition:
This depends on the type of wire and size being used. With a 1.2mm (.045 Dia) wire, 120 - 160 gm/min of carbide would be a typical deposition rate. Accurate digital scales are recommended for checking the flow rate. Too much carbide flow is detrimental and will cool the molten weld-pool too quickly, as well as not allowing the weld matrix to fully encapsulate the carbides leading to chipping out or weld spalling. Conversely, too little carbide in the weld will cause premature wear results.
Automatic/Manual Mode:
A Toggle switch changes the MODE between Manual (MAN.) and Automatic (AUTO) functions. On MAN. the feeder will be activated and the carbide will flow until the control box is switched off or the MODE switch is returned to the AUTO position. Moving the switch to the AUTO position activates the switch circuit which enables the use of a foot pedal or reed switch to turn the feeder on and off. A foot pedal is included as part of the system package and reed switches are available as an optional part. The reed switch is a current sensing switch which can be attached to the welding earth lead, and automatically turns the feeder on and off when you start and stop welding.
Pre-Heating:
This is largely determined by the type/composition and carbon content of the base material. High carbon steels like Chromoly and high strength low alloy types like Bisalloy, Wearalloy need preheat. The temperature that these materials will need to be heated to is also dependent on the thickness of the steel. A typical preheat temperature for GET (ground engaging tools) would be 150 degrees Celsius. We suggest calling us to discuss the job if you are unsure.
Reusing the Tungsten:
Approximately only half the carbide flowing down the feed tube will enter the weld-pool so it is a good idea to collect the excess and re-cycle it. Sieves are available and are useful for removing dust, weld spatter and other impurities.
Welding Techniques:
Single layer welds are recommended as multi-layer welds have a tendency to melt the carbide in the lower layer which will produce a very hard weld deposit that then becomes prone to chipping or spalling out. A weave or oscillation is recommended from ½” - 1” wide, and even wider should the application call for it. The aim point for the carbide is critical and should be directed into the last ½ of the molten weld pool. Aiming too close to the arc will cause the carbides to melt causing a brittle weld structure.