Mined products are today used in almost every consumer product, making mining a vital component of modern society. And since mining is critical to modern life, the manufacture of mining equipment is equally important.
It takes great precision and efficiency to achieve the structural integrity and massive scale required of the machinery used in mining. From towering cranes to intricate machinery, welding technologies lay the foundation for building strong and reliable mining structures, ensuring their durability and performance.
Elemet Group understands the importance of welding for mining equipment manufacturers and provides state-of-the-art welding solutions to accomplish your projects. Our welding services are quality-focused and aim to help you increase productivity and optimize the maintenance and repair of mining equipment.
Importance Of Welding in Mining Machinery
Welding is a vital part of the custom fabrication process. While it seems complex and modern, it is actually a relatively old technology with the earliest traces back to the Bronze Age. In its early years, it was not as sophisticated as it is now, but it was impactful enough to revolutionize how tools were made. Its advancement was slow in the formative years, but once it gained momentum at the beginning of the 19th Century, it didn’t stop.
Welding now plays a vital role in industrial reforms and the manufacture of welding consumables in multiple sectors, including infrastructure, transportation, manufacturing, industrial, agriculture, and mining. It is an essential process in metal fabrication that helps join two or more pieces of metal together. If done correctly, it results in a solid and durable weld that will not break easily, thus minimizing the chances of accidents or injuries.
Different components make up equipment, and welding helps put them all together and give them function. This leads to the creation of reliable and safe equipment that facilitates miners in their tasks. In addition, welding also helps improve productivity by reducing loss of production associated with equipment breakdown.
Strong, high-quality welds maintain the overall strength of a structure, making it capable of withstanding the rigors of mining environments, thus ensuring longevity and consistent performance for uninterrupted workflow and higher project efficiency.
Commonly Used Welding Techniques of Mining Equipment Manufacturers
There are four popular welding processes:
TIG Welding (Gas Tungsten Arc Gas Welding – GTAW/TIG)
This welding method is primarily used for fusing thick sections of non-ferrous metals and stainless steel. It uses a fixed consumable tungsten electrode to produce weld. You create an arc between the base metal and the non-consumable tungsten electrode, and once the arc hits the base metal, a molten weld pool will form. It is a time-consuming process and also requires high-level skill.
When using the TIG technique, the composition of the base metal matters since the percentage of chromium will affect the melting temperature. It is best performed indoors, away from the elements, because it requires a constant flow of gas.
MIG Welding (Gas Metal Arc Welding – GMAW/MIG)
The process requires the use of a shielding gas along the wire electrode, heating the two metals to be joined. The use of gas helps protect the workpiece from contamination. Inert gases or gas mixtures such as argon and helium are typically used. You will require constant voltage with direct-current power sources, which is most common for industrial welding processes.
SMAW Welding (Shielded Metal Arc Welding – SMAW)
The process entails following a manual process with a stick to form an arc between the stick and the metals to be joined while using an electric current. It is a popular technique for the construction of steel structures and in welding iron and steel for industrial fabrications.
Stick welding doesn’t have an appealing finish and is best used for welds that are not visible in the finished product. It is an excellent welding technique for mining machinery repairs since it works well on rusted, painted, and dirty surfaces.
Flux Cored Arc Welding (FCAW)
This welding method was developed as an alternative to shield welding and is mostly used for construction services and mining equipment manufacturers. It offers high speed and portability and a great deal of flexibility in terms of angles, voltage, polarity, and speed. Flux Cored Arc is best done outside or under ventilation hoods since it produces a great deal of smoke and fumes.
What Materials Are Used in Mining Machinery?
Metal is the primary material mining equipment manufacturers use. Different metals are used to fabricate various components of mining machines, equipment, and operations. And just as each piece of equipment has a purpose to serve, so does the type of metal used.
Common metal materials mining equipment manufacturers use include stainless steel, aluminum, copper, brass, heat-resistant alloys, abrasion-resistant alloys, corrosion-resistant alloys, carbon alloy, nickel alloy, non-ferrous steel, and chrome carbide overlay plates.
Stainless steel, however, features more prominently because of its strength, which makes it suitable for heavy-duty mining applications. Stainless steel can also withstand high temperatures, making it suitable for making mining components that need to work in high-heat conditions.
Element Group: Our Experts Are with You
Welding supports metal and steel fabrication, enabling the creation of custom-designed equipment that meets the needs and conditions of mining sites. Elemet Group consists of experienced engineers with advanced skills who understand how to design and manufacture complex mining equipment. We offer innovative solutions and employ the latest technology to optimize equipment and machinery.
Whether you want us to develop new designs, improve existing equipment, repair broken machinery, or assist with maintenance tasks, we are here to help and support your business. Contact us today to learn more about our welding solutions or request a free quote.