ウェルディングアロイズ・ジャパン List of Products and Services

We would like to introduce our "Smart Brushing." When applying overlay welding to the outer surfaces of screen tubes and inner tubes in boiler furnaces, it is necessary to remove the black scale from the pipe surface for quality control purposes. Our pipe outer surface polishing device can automatically polish the pipe surface using a grinder that contacts the pipe while the pipe is rotated and moved. 【Features】 ■ Compatible pipe sizes: OD 38.1mm to 76.2mm (please consult us for other sizes) ■ Compatible pipe lengths: Long lengths can be accommodated ■ Achieves uniform surface finishing ■ Cost reduction through automation *For more details, please refer to the PDF document or feel free to contact us.

• Wafer processing/polishing equipment

The type of material being transported causes the flights and shafts of the screw conveyor to wear out quickly, leading to replacement costs for those parts and issues such as decreased equipment operating rates. Our company achieves extended life by automatically applying hardfacing welding to the areas of the screw conveyor that experience significant wear. In addition to restoring the shape through welding, we also perform surface modification after replacing the blades, linings, and chips. We also manufacture the screw body itself. 【Features】 ■ High-quality construction achieved through automation ■ Reduction of maintenance costs ■ Improvement of equipment operating rates *For more details, please refer to the PDF document or feel free to contact us.

• Other processing machines
• Repair Agent
• Calibration and repair

In fluidized bed boilers, high-temperature sand and ash containing non-combustible materials discharged from the furnace bottom cause rapid wear of components such as screw conveyor flights and shafts, leading to replacement costs and decreased equipment operating rates. Our company achieves extended service life by automatically applying hardfacing welding to the areas of screw conveyors that require wear resistance using the "Tri-S Method (TM)" where significant material loss occurs. 【Features】 ■ High-quality construction achieved automatically ■ Reduction in equipment maintenance costs ■ Improvement in equipment operating rates *For more details, please refer to the PDF document or feel free to contact us.

• Repair Agent
• Calibration and repair

The equipment of hydropower plants is exposed to high cavitation, erosion wear, and vibration, particularly in the scroll casing, guide vanes, and runner blades. We repair turbine and mantle damage using special welding materials, primarily in Europe. Additionally, we also sell a welding material with excellent cavitation resistance called "CAVITALLOY." 【Features】 ■ Achieves high-quality construction through automatic overlay welding depending on the application ■ Reduces equipment maintenance costs ■ Improves equipment operating rates *For more details, please refer to the PDF materials or feel free to contact us.

• Repair Agent
• Calibration and repair

The Fe-Zn compounds generated in the molten zinc galvanizing bath undergo corrosion-related thinning when the temperature exceeds 450°C. By using the high-temperature corrosion-resistant welding material "GALVALLOY" manufactured by Welding Alloys, which maintains a high market share in Europe, and performing automatic overlay welding, we achieve a longer lifespan for the molten zinc galvanizing bath. "GALVALLOY" has high-temperature corrosion resistance comparable to that of expensive cobalt-based welding materials, while being reasonably priced and economical. 【Features】 ■ Achieves high-quality construction through automatic overlay welding ■ Extends lifespan and reduces costs by using the high-temperature corrosion-resistant welding material "GALVALLOY" ■ Reduces ancillary work such as replacements through prolongation ■ Capable of accommodating new production for molten zinc galvanizing baths *For more details, please refer to the PDF document or feel free to contact us.

• stainless
• Other metal materials

We would like to introduce a case where our products have been adopted by a steel mill. It is possible to replace the lower body section of the blast furnace's tuyere with products made from hardfacing plates "Hardplate" and "Hardlite." By using high-temperature resistant materials for the filler, we contribute to longer service life. In addition, our products have been adopted for measures to extend the life of sintering furnaces, chutes, and for hardfacing repairs of crane wheels. 【List of Adoption Cases】 ■ Measures for extending the life of blast furnaces ■ Measures for extending the life of sintering furnaces (Sinter star) ■ Measures for extending the life of sintering furnaces (screen, sinter bars, etc.) ■ Measures for extending the life of chutes ■ Measures for extending the life of various pipes and gates ■ Hardfacing repairs of crane wheels *For more details, please refer to the PDF document or feel free to contact us.

• Steel
• Other metal materials

We would like to introduce a case where our products were adopted by a cement factory. By processing and attaching the overlay plates "Hardplate" and the ultra-lightweight "Hardlite" products to the surface, we can significantly extend the lifespan of the mantle and cone cave. In addition, these products have been adopted as measures to prolong the lifespan of hammer crushers and rotary kilns. [List of Adoption Cases] ■ Measures to extend the lifespan of dam rings and airflow ■ Measures to extend the lifespan of mantles and cone caves ■ Measures to extend the lifespan of hammer crushers ■ Measures to extend the lifespan of roller presses ■ Measures to extend the lifespan of sieves and screens ■ Measures to extend the lifespan of rotary kilns *For more details, please refer to the PDF materials or feel free to contact us.

• Steel
• Other metal materials

We offer a variety of wear-resistant plates, including "Hard plate" made by welding wear-resistant materials to base materials such as SS400, and "Hard lite," which is ultra-thin. We also support the design and manufacturing of wear-resistant fabricated products made from wear-resistant plates. Additionally, we provide cutting and bending processing for delivery according to customer requests, as well as installation work on-site. 【Features】 ■ Welding wear-resistant materials to base materials such as SS400 ■ Support for the design and manufacturing of wear-resistant fabricated products ■ Delivery with cutting and bending processing, and on-site installation work ■ A wide variety of wear-resistant plates available *For more details, please refer to the PDF document or feel free to contact us.

• Steel
• Other metal materials

Tower tanks are used for various purposes, but their inner walls corrode and experience material loss over time. Until now, areas of material loss due to corrosion have been temporarily addressed through methods such as plate installation and coating, but various challenges have been reported. Our company proposes "automatic build-up welding" through "smart welding" as a solution to this material loss, achieving extended service life. The on-site automatic welding system consists of a fixed jig, a welding torch movement mechanism, a control device, and a welding power source, with each component designed to be compact and lightweight, allowing for transport in and out of narrow manholes. 【Features】 ■ Capable of transport in and out of narrow manholes ■ Achieves high-quality welding construction automatically ■ Realizes corrosion and erosion resistance in various tower tank inner walls ■ Contributes to improved equipment operating rates *For more details, please feel free to contact us.

• Welding Machine

We would like to introduce our company's "Application Cases in the Biomass Power Generation Industry." Biomass power generation, positioned as one of the renewable energy sources, is generated using biomass fuels such as wood chips, wood pellets, and palm kernel shells (PKS). Our company addresses the challenges faced by these facilities (thinning due to corrosion and wear) with our overlay welding technology. [Examples] ■ Boiler panel construction at our factory ■ Screw construction at our factory ■ Thinning countermeasures for cyclones using hardened overlay plates ■ Air nozzle top surface construction at our factory *For more details, please refer to the related link page or feel free to contact us.

• Processing Contract
• Other contract services

Here are some application examples from the mining industry. In the mining and quarrying industry, crushers are used, and the materials being crushed include sandstone, silica, limestone, tantalite, quicklime, talc, and various others. Our company extends the lifespan of crushers by applying hardened overlay welding. 【Examples】 ■ Crusher mantle for crushed stone, manufactured at our factory ■ Crusher concave for crushed stone, manufactured at our factory ■ Gyratory crusher mantle, manufactured at our factory ■ Gyratory crusher mantle, installed on-site *For more details, please refer to the related links page or feel free to contact us.

• Processing Contract
• Other contract services

Here are some examples of applications in the paper industry. The black liquor recovery boiler burns black liquor (Na2SO4), which is the waste liquid from caustic soda (NaOH) used in the paper-making process, to recover green liquor (smelt, primarily composed of Na2S), which is a raw material for caustic soda. Additionally, the heat generated during the combustion of black liquor is utilized for steam in the factory and for power generation. Since the furnace walls are damaged by sulfide corrosion, our company manufactures overlay panels with damage countermeasures to extend their lifespan. [Examples] - On-site installation of coal pulverizer mill table liners - Panel installation for black liquor recovery boiler at our factory - Screw installation at our factory *For more details, please refer to the related links page or feel free to contact us.

• Processing Contract
• Other contract services

Here are some case studies from the cement industry. Cement production consists of raw material processing, firing, and finishing processes, and wear occurs in all of these processes due to grinding and transportation. Among these, the most wear occurs in the raw material grinding mills (raw mills) and slag mills, and we regularly perform regeneration inside the mills. [Case Studies] - On-site construction of rollers for the slag grinding mill at our factory - On-site construction of rollers for the cement raw material grinding mill - On-site construction of table liners for the slag grinding mill - On-site construction of the furnace wall for the oil coke-fired boiler *For more details, please refer to the related links page or feel free to contact us.

• Processing Contract
• Other contract services

Here are some examples of applications in the steel industry. In the processes of ironmaking, steelmaking, rolling, and finishing at steelworks, there are issues related to wear and corrosion. Regarding the maintenance of blast furnace-related equipment in the ironmaking process, the implementation period is constrained by downtime. Our company achieves regeneration within this limited downtime in the PCI mill. [Examples] - On-site installation of PCI mill table liners - On-site installation of PCI mill rollers *For more details, please refer to the related link page or feel free to contact us.

• Processing Contract
• Other contract services

We will introduce applicable examples from the power generation industry for both business and private use. In thermal power generation facilities, there is a demand for higher efficiency, improved operating rates, and longer lifespans. Our company enhances the wear and corrosion resistance of equipment surfaces through a build-up welding technique that modifies the surface by selecting appropriate welding materials for the base material, thereby achieving regeneration and prolongation of equipment life. [Examples] ■ Construction of coal pulverizer rollers at our factory ■ On-site construction of coal pulverizer table liners ■ Simultaneous construction of coal pulverizer rollers and table liners ■ On-site construction of coal-fired boiler furnace walls ■ Construction of eccentric shaft sliding parts at our factory ■ Thinning countermeasures for separator frames using hardened build-up plates *For more details, please refer to the related link page or feel free to contact us.

• Welding Machine
• Processing Contract
• Other contract services

Our company has developed and is implementing an in-house device for overlay welding on the outer surface of pipes used in areas prone to wear, such as screen tubes and various nozzles in boiler furnaces, to ensure resistance to corrosion and wear. Additionally, it is possible to perform bending processing on the welded overlay pipes. We have also obtained a patent for the cooling method of these pipes. 【Features】 ■ In-house developed device for overlay welding on the outer surface of pipes ■ Bending processing can also be performed on the welded overlay pipes ■ Patent obtained for the cooling method of these pipes *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

The "OG device" is an exhaust gas treatment facility that safely collects high-temperature gas containing high concentrations of carbon monoxide generated from the converter after cooling and dust removal in a non-combustion state. The inner wall is exposed to high temperatures from the exhaust gas of the converter, and as the jacket's inner wall wears and oxidizes in a short period, it may require replacement, resulting in a decrease in equipment operating rate. As a solution to such problems, it is recommended to perform wear-resistant overlay welding using an automatic welding system on the entire inner wall of the jacket. Specifically, through this wear-resistant overlay welding, automatic welding will be carried out on the entire inner wall of a jacket approximately 2.5m long (material: SS400, thickness: 12mm, pipe diameter: 600mm) using a dedicated welding system from WA (WAMS D-2-trak System) and welding materials (307-O, CV-O). The wear-resistant jacket created using this special construction method with an automatic welding system contributes to maintaining the operating rate of the converter. *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Other contract services
• Welding Machine

The PCI mill experiences wear on its components due to long operational periods and the use of poor-quality coal. Therefore, wear-resistant measures for the table liner, rollers, and separators, as well as hardfacing technology for regeneration, are required. Since the maintenance period for the PCI mill is limited, regenerating within the mill through hardfacing welding eliminates unnecessary work and reduces maintenance costs during frequent downtime. With automatic hardfacing technology that allows for simultaneous construction of three rollers or the simultaneous construction of one roller and the table liner, regeneration within the mill can be performed more easily and safely, enabling the completion of necessary maintenance within the limited downtime. Our company is continuously developing the essential technologies required for such innovative hardfacing applications. *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine
• Processing Contract
• Other contract services

The body liner, which controls the flow of crushed material, wears out due to hot air and the crushed material. Since the inner wall of the mill gets damaged, it is necessary to replace the body liner, which takes time and costs, resulting in significant effort. To eliminate the disadvantages of replacement, our company performs hardfacing welding inside the mill. As a result, we have successfully regenerated the body liners of bowl-type mills and the deflector plates of MVM-type mills. 【Benefits of performing the work inside the mill】 ■ No need for replacement ■ Improved wear resistance through hardfacing regeneration ■ Extension of replacement timing ■ Cost reduction *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine
• Processing Contract
• Other contract services

In this construction, the work was carried out with the rollers removed from the mill, in conjunction with the maintenance of the roller bearings. In the installation situation within the mill, the rollers are supported by the upper structural members, but the removed rollers were fixed in a stable position with the supporting structure underneath. Simultaneous work on three rollers was conducted in the temporary work area outside the mill. After semi-automatic repairs were performed on the heavily worn rollers with wave-like wear, automatic hardfacing was carried out using a wire feeding speed automatic control system. Thanks to the technology adopted this time, it is now possible to perform external work on super-large mill rollers that have a significantly uneven wave-like wear surface. 【Construction Status】 ■ Roller removal ■ Transportation ■ Inversion and installation ■ Welding work *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine
• Processing Contract
• Other contract services

Welding Alloys Japan Co., Ltd. adopts a surface modification method using build-up welding and is engaged in maintenance services for base material surfaces or damaged base material surfaces. Our business involves regenerating equipment such as power (for business use and self-generation), cement, steelmaking, papermaking, petrochemicals, and construction machinery at our factory, as well as conducting on-site regeneration of equipment within customer plants. We contribute to shortening construction periods and reducing costs in equipment maintenance by working closely with our customers. 【Business Content】 ■ Wear-resistant and corrosion-resistant welding construction, sales of welding materials (flux-cored wire), and automatic welding systems. *For more details, please download the PDF or feel free to contact us.

• Welding Machine