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Universal Wear Solutions

Product Welding Instructions
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Table of Contents

Safety

General/Safety information 4

Signal Words 4

Personal Safety 4

ESCO AR Plate

Welding, Preparation, Welding Procedure 5

Infinity Bi-Metallic Buttons, Blocks, Bars and Runners

®

Welding, Preparation, Welding Procedure 6

Infinity Overlay Plate

Cutting, Welding, Attachment Methods, Fillet Weld, Plug Weld 7

Studs, Bolts, Butt Joints, Special Application Welding, Fillet/Plug Weld 8

Additional Overlay Protection 9

Infinity Cast Tiles

Welding, Preparation 9

Welding Procedure 10

Introduction
The instructions contained in this manual are the recommended procedures for installing ESCO Universal Wear
Solutions products. The products include ESCO AR plate and the full family of Infinity Bi-Metallic Products: But-
tons, Blocks, Bars, Runners, Wear Tiles, and Chromium Carbide Overlay Plate.
For additional information on Universal Wear Solution Products, please refer to product specific instructions
provided by ESCO or contact your ESCO representative.

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Safety
General/Safety Information
The safety practices described in this manual are meant as guidelines for safe operation under most conditions and
are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of
others results from putting into practice your knowledge of the correct operating procedures.
Signal Words
Throughout this manual are statements preceded by a special attention symbol: The symbol is used with the
following signal words to attract your attention to information of special priority. Read the paragraphs carefully and
make sure you understand their significance, especially the possible causes of injury.

WARNING: A statement preceded by “WARNING” is information that should be acted upon to prevent serious
injury.
CAUTION: A statement preceded by “CAUTION” is information that should be acted upon to prevent machine
or equipment damage.
Additional signal words that are not preceded by the attention symbol are:

IMPORTANT: A statement preceded by the word “IMPORTANT” is information that possesses special
significance.
Tip: A statement preceded by “Tip” is information that is handy to know and may make your job easier.
Personal Safety
WARNING: When performing the work described in these instructions, always work safely and use proper
safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing
protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing
maintenance work. To avoid injury to others, keep bystanders well out of the way.

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ESCO AR Plate
Welding
Recommended Electrodes
When welding to low alloy steel When welding to Manganese
Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16
Gas Metal Arc Welding (GMAW) E70S-1 or E70S-6 EC309 or ER309
Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M (dual shield) E309T-1

Preparation
ESCO AR 400 and ESCO AR 500 plate may be welded using conventional, low hydrogen welding
processes.

IMPORTANT: To properly control moisture, electrodes that have been exposed to the air for more than one hour or
were not stored in an airtight container should be baked in a ventilated oven at 260°C / 500°F for two hours prior
to use. After baking, the electrodes can be stored in a ventilated holding oven at 65°C / 150°F. Remove only one
hour’s supply at a time.

Recommended Minimum Preheat Temperatures

ESCO AR 400 to Plate ESCO AR 500 to Plate Plate to Casting Plate to Manganese
Up to 25mm / 1.00in. Sections 20°C / 70°F 95°C / 200°F Follow preheat
25mm / 1.00in. to 51mm / 2.00in. 65°C / 150°F 120°C / 250°F requirements for Do not preheat
Over 51mm / 2.00in. 120°C / 250°F 175°C / 350°F the casting alloy

Welding Procedure
When welding, use short stringer beads and remove slag after each pass. Interpass temperature should be kept
below 260°C / 500°F for low alloy steel, and below 120°C / 250°F for Manganese Steel. However, for fabrications
involving both castings and plate components, preheat and interpass temperature requirements for the casting shall
take precedence. Post weld heat treatment should not be applied if original hardness levels are to be maintained.

WARNING: When performing the work described in

these instructions, always work safely and use proper
safety equipment to help avoid injury. Always wear hard
hat, gloves, safety shoes, eye protection, hearing protection
and fall protection per regional, national and site
requirements (e.g. OSHA, MSHA) when performing
maintenance work. To avoid injury to others, keep
bystanders well out of the way.

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Infinity Bimetallic Buttons, Blocks, Bars and Runners

®

Welding
Recommended Electrodes
When welding to low alloy steel When welding to Manganese
Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16
Gas Metal Arc Welding (GMAW) E70S-1 or E70S-6 EC309 or ER309
Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M (dual shield) E309T-1

Preparation
Prior to welding, remove all slag and scale from the surface to be welded. To ensure maximum weld strength, the
surface should be clean and as flat as possible.

CAUTION: DO NOT preheat Infinity Bimetallic Buttons, Blocks, Bars or Runners. Preheat may be necessary
for the parent metal only. For heavy sections (greater than 40mm / 1.50in.), the following minimum preheat
temperatures should be used. No preheat is required for Manganese Steel.

Working Temperature > 5°C / 40°F: 95°C / 200°F

Working Temperature ≤ 5°C / 40°F: 175°C / 350°F

Welding Procedure
IMPORTANT: Welds should not come in contact with the Chrome White Iron (CWI) section. A minimum gap of
2mm/0.06in. should be maintained. Failure to do so could result in cracking.
For best results, the bimetallic button or block should be clamped and tack welded into position prior to final weld-
ing. To minimize heat input, maximum run lengths should be 50mm / 2.00in. to 70mm / 2.50in. Continuous welds
should not be used.
Interpass temperature should be kept below 260°C / 500°F for Low alloy steel, and below 120°C / 250°F for
Manganese Steel. The parent metal should only be warm to the hand 150mm/6.00in from the weld when working
with manganese steel. No post heat is required.

CORRECT INCORRECT
2mm / CWI
0.06in.

Mild Steel

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Infinity Overlay Plate

®

Cutting
The recommended method for cutting overlay plate is Plasma Arc. Cut from the mild steel side. Cutting from the
overlay side will deposit carbides on the mild steel which, unless ground off, can cause the weld to fail. An
abrasive saw with a silicon carbide wheel, while slow, is also a viable option. If neither of these processes is
available, carbon arc cutting can be used. However, due to the inaccuracies and extensive clean up involved, this is
not the preferred method.
Welding
Recommended Electrodes
When welding to mild steel When welding to dissimilar metal
Shielded Metal Arc Welding (SMAW) E7018 E309-16
Gas Metal Arc Welding (GMAW) E70S-1 or E70S-6 EC309 or ER309
Flux Cored Arc Welding (FCAW) E70T or E71T E309T-1

Attachment Methods
Prior to welding, remove all slag and scale from the surfaces to be welded. Preheating of the overlay plate is not
required, but preheat requirements for the parent material should still be followed.

IMPORTANT: Attachment welds should not come in contact with the overlay material. Failure to follow this could
result in cracking. Additionally, the overlay material has no structural strength, and therefore should not have
anything welded to it.

Fillet Weld CORRECT INCORRECT

2mm /
Remove slag and scale from the area to be welded. 0.06in. CWI
Leave a 2mm / 0.06in. gap between the fillet weld and
the overlay material as shown to the right. This will help Mild Steel
prevent cracking.
Fillet Weld

Plug Weld CORRECT INCORRECT

Recommended plug weld size is 25mm / 1.00in. x 2mm /
76mm / 3.00in. spaced every 381mm / 15.00in. to Overlay 0.06in. Overlay
610mm / 24.00in. Slag and scale should be removed,
and there should be a 2mm / 0.06in. gap between the Mild Steel Mild Steel
weld and overlay material as shown to the right.
Plug Weld

WARNING: When performing the work described in

these instructions, always work safely and use proper
safety equipment to help avoid injury. Always wear hard
hat, gloves, safety shoes, eye protection, hearing protection
and fall protection per regional, national and site
requirements (e.g. OSHA, MSHA) when performing
maintenance work. To avoid injury to others, keep
bystanders well out of the way.

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Infinity Overlay Plate Continued

®

Studs Overlay
Minimum recommended stud size is 10mm / 0.38in.
Special care should be taken when welding studs onto Mild Steel
thinner backing plates to avoid potential burn through.
Weld
Stud
IMPORTANT: Studs can ONLY be attached to the mild
steel side.

Stud Weld
Bolts
The chromium carbide overlay is too hard and brittle to Machined insert
machine using traditional methods. To get around this, a Overlay Overlay
machined mild steel insert is welded into a precut hole.
The minimum recommended bolt size is 10mm / 0.38in.
Mild Steel Mild Steel
Countersunk holes can also be cut directly using spark
erosion. Weld

Butt Joints Overlay weld (optional) 3mm / 0.13in.

After removing slag and scale from the weld surface,
bevel the edge leaving a 3mm / 0.13in. land. When Overlay Overlay
welding the sections together, care must be taken to
Mild Steel Mild Steel
avoid burning through the mild steel. The gap in the
overlay material can be filled with overlay weld. In Weld
applications where the overlay material side cannot be
reached, like in a pipe, a root pass should be made
with austenitic stainless steel rod. This will ensure that Overlay Overlay
the subsequent welds will not come in contact with the
hardfacing, thus reducing the risk of the weld cracking. Mild Steel Mild Steel

Weld Austenitic stainless steel

rod weld (optional)
Special Application Welding
The standard welding procedures described above may be insufficient in applications where a thinner mild steel
backing plates (6mm / 0.25in. or less) is attached to something that experiences a lot of flexing, like a dragline
bucket. In these special applications, the following welding procedure may be used.

Recommended Electrodes Recommended Shield Gas

Shielded Metal Arc Welding (SMAW) E309-16 N/A
Gas Metal Arc Welding (GMAW) EC309 or ER309 98% Argon + 2% Oxygen
Follow wire manufacturer’s
Flux Cored Arc Welding (FCAW) E309T-1
recommendations

Austenitic
Fillet/Plug Weld: stainless Overlay
Remove slag and scale from the area to be welded. steel weld
Use the stainless steel material as recommended above. Mild Steel
Apply a fillet weld the full height of the plate as shown to
Suitable when overlay with a thin mild steel backing (6mm/0.25in.
the right or less) is used in an application where it experiences a lot of flexing.
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Infinity Overlay Plate Continued

®

Additional Overlay Protection

The low hydrogen weld material is much more vulnerable to abrasion than overlay material, and may prematurely
wear. To avoid this, plug welds, fillets, and joints welded with low hydrogen rod located in abrasive areas can have
overlay material applied. Overlay material can also be applied to gaps between overlay plate and bolt heads to
protect against wear. A list of compatible electrodes is below.
Manual Electrode Semi-Automatic Electrode Using the manufacturer’s recommended
amperage setting, the overlay material can be
Lincoln Wear shield 60 Lincore 60-0
applied using either a weave or stringer method.
Stoody Coated Tube Stoodite 2134 100HC, 101HC, 0, G
If possible, it is recommended to apply two
McKay Hard alloy 55 255-0 overlay layers. Preheating to 190°C / 375°F is
Alloy Rods 40 40 necessary when welding to castings or alloy
Bohler Fox dur 65 Fox dur 650KS plate.
Eutectic N6006 -
Rankin 4 H
Stellite Delchrome 94 100-0
Amsco Superchrome Superchrome S/A
Sodel Sodel 2024 Sodel 8240

Infinity Cast Wear Tiles

®

Welding
Recommended Electrodes
When welding to low alloy steel When welding to Manganese
Shielded Metal Arc Welding (SMAW) E7016 or E7018 E309-16
Gas Metal Arc Welding (GMAW) E70S-1 or E70S-6 EC309 or ER309
Flux Cored Arc Welding (FCAW) E70T-5 or E71T-12H4M (dual shield) E309T-1

Preparation
Prior to welding, remove all slag and scale from the surface to be welded. To ensure maximum weld strength, the
surface should be clean and as flat as possible.

CAUTION: DO NOT preheat Infinity Cast Wear Tiles. Preheat may be necessary for the parent metal only. For
heavy sections (greater than 40mm/1.50in.), the following minimum preheat temperatures should be used.
Do not preheat manganese steel.
Working Temperature > 5°C / 40°F: 95°C / 200°F
Working Temperature ≤ 5°C / 40°F: 175°C / 350°F

WARNING: When performing the work described in

these instructions, always work safely and use proper
safety equipment to help avoid injury. Always wear hard
hat, gloves, safety shoes, eye protection, hearing protection
and fall protection per regional, national and site
requirements (e.g. OSHA, MSHA) when performing
maintenance work. To avoid injury to others, keep
bystanders well out of the way.

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Infinity Cast Wear Tiles Continued

®

Welding Procedure
CORRECT INCORRECT
IMPORTANT: Welds should not come in contact with 2mm /
0.06in.
the Chrome White Iron (CWI) section. A minimum gap CWI
of 2mm / 0.06in. should be maintained. Failure to do so
could result in cracking. Mild Steel

Standard Wear Tiles

For best results, the Cast Wear Tile should be clamped
and tack welded into position prior to final welding. To
minimize heat input, maximum run lengths should be
50mm / 2.00in. to 70mm / 2.50in. Continuous welds
CORRECT CORRECT
should not be used.
2mm /
CWI 0.06in.
Interpass temperature should be kept below 260°C /
500°F for low alloy steel, and below 120°C / 250°F
for Manganese Steel. The parent metal should only be Mild Steel
warm to the hand 150mm / 6.00in. from the weld. No Jacketed Wear Tiles
post heat is required.

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