130 7596-1084 (1 International Standard (tt) 7595 ‘Treinen ONG Ton Fon TANOA OG TIONGERATH APRN OF BRAIN No CTANAAFHGALRINONGAWGATION HTERNATIONALEO& NORUALEATIN Socketing procedures for wire ropes — Molten metal socketing Procédls de terminaison des cibles métaliques ~ Manchonnage & aide de métal fonds First edition — 1984-10-15 at lon]? 49707174 PERE neDiEay BIS LIBRARY UDC 621.86.065.3 Ref. No. 180 7595-1984 (E) Descriptors: iting eauioment sieForeword anette Interatonsl Organization for Standadaation) i a worldwide federation ot Sreane sanderds bodies 1S member bodies). The work of propring neon cr ‘Standards i rag ana Standard ISO 7585 was prepared by Technical Committe IS0/TC 11, ‘Round steel link chains, iting hooks and accessories © International Organization for Standardisation, 1904 Printed in SaitatandINTERNATIONAL STANDARD. 1SO 7595-1984 (E) Socketing procedures for wire ropes — Molten metal socketing 1 Scope and field of application ‘This Intemational Standard provides guidance on recom mended practices for the metal socketing of wire ropes pro- ‘Guced in accordance with ISO 2406. The recommendations ae ‘iso generally applicable to the socketing of other wire ropes. ‘Wen socketing ropes which have wire tensile grade’ greater than 1960 MPa (N/mm, special precautions ‘may be necessary and the rope supplier should be consulted Rope terminations made by socketing in accordance with this Intemational Standard may be used for determining the break: ing load of wire ropes in accordance with ISO 3108. 2. References 150 2408, Stee! wire ropes for general purposes — Characteristics.) 180 3100, Steet wire ropes for general purposes ~ Determina tion of actual breaking lood. 150 3180/1, Sockets for wie ropes — Port 1: General cond tions of acceptance? 150 4981, Plain beorings — Lead and tin casting alloys for ‘muller pon bearings. 3. General 150 3180/1 specifies the dimensions ofthe sockets for goneral purpose ropes, The sockets and socketed assemblies shall pass the prototype tests in that International Standord. ‘Sockets for spiral strands, locked coll ropes, and for breaking ond tests may have special requirements, 4 Preparation of the rope end {A sulficient length of the rope should be externally cleaned on ‘both sides ofthe designated point of cut by wiping wit a clean dry doth oF a cloth dipped in solvent. This cleaning should be ‘confined to the length of rope to be threaded ough the ‘socket TA presont at the stage of rot Ravan of 150 2409 1872) 2) At present atthe sage of att 4.1. Seizing of the rope ‘Two types of sozing ae recognized. a) Temporary seing is used when cutting non-preformed ‘opes, multistand ropes, spiral strands, ele. A temporery ‘seizing may be applied to the rope an each side of the cut. ‘These seizing should be such 2s to hold the strands and wires reasonably wel in postion during the cutting opera- tion Permanent seizing is used to hold the wires and strands ‘during the eocketing operation. A permanent seizing is ‘plied to that part of the rope which is partly within or ‘adjacent to the mauth of the socket when the operation is ‘completed. Permanent sizing should be in position before cutting the rope. “The permanent seizing should 1) ensure thet the wires and strands are undisturbed ‘during eacketing operations: 2) permit the passage of the seized rope through the ‘mouth of the socket. 42 Seizing material “The seizing material should be tinned or galvanized soft wire oF strand for galvanized ope, and bright or galvanized sof wire or strand for bright rope. ‘Alternative materials may be used but care shouldbe taken that they do not cause electrolviic action in sarvce, and that they fre capoble of withstanding the temperatures involved Copper and tross wires should not be used for sezings. Plastic seitings of proven suitability may be allowed. 4.3. Cutting the rope “The rope should be cut by any suitable method which does not disturb the positon ofthe wires below the permanent seizing Cutting wath an abrasive whee! s to be prefered. When cutting by percussive or shearing methods special cae is required. Oxy ‘acetylene cutting should not be employed owing tothe rsk of hheat damage tothe wires ond lubrication, and tothe difiultios ff separating the wires during subsequent socketing opereISO 7595-1984 (E) 5 Preparation of the brush 5.1. Preparation of the rope Before threading the socket on to the rope, all drt, grease or scale should be removed from the inside of the basket. ‘The cut end of the rope should be threaded through the socket ‘aking care that the basket wals do not come into contact with ‘the uncleaned part of the rope. If this doss occur, the rope should be unthreaded and the socket walls recleaned. Aer ‘threading, the temporary seizing atthe point of cut should be ‘emoved and the strands unlaid as far back as the permanent sazing, and swept outwards to low opening of the wires. The opening angle of the final brush should not exceed 45° {rom the vertical for stranded ropes (see figure Tal). For locked coil ropes and spiral strands the wires should be Lniaid and swept outwards a an angle not exceeding 60° from the vertical [ee figure 1b) When a rope contain a steel core, the wires of the core should ‘be completely unlaid to form an open brush, |Whon 9 rope contains a fore core, the core should be cut and removed dow to the permanent seizing. To avoid damage 10 the core by molten metal at the cut end, the core may be pro. Ww 4a) Stranded ropes tected by a plug of a suitable heat-resistant material, Such pro- tection is paniculaly important if the core is of synthetic materia When preformed round strand ropes are being socket, a longer Piece of the fibre core may be removed and replaced by @ suitable Stand. In this case the permanent sxzing should be removed, the ‘ope unlsid overa longer distance, the fbve core cut and the strand inserted, the rope strands closed again and the permanent seizing ‘reapplied at its orginal postion. The roplacernent core should be then completly unisid to form an open brush, ‘The following diameters, dp, for the replacement core are ‘ecommended = ‘ropes with 6 strands, dy = 0,95 100,40 dy ropes with 8 strands, dy = 0,47 100,52 dy where ‘dyy_ is the monsured diameter of the rope. ‘After dealing with the core, the Individual wires from the ‘srands should be unloid (but not straightened) and @ brush formed. Core shouldbe taken not o bend the wires or strands to an ex cessive angle at the permanent selzing, since this may couso ‘premature fatigue falas in tho completed assembly. 00, “Re 1b} Locked coll ropes and spiral strands Figure’— Opening angie of the brush5.2 Cleaning and degreasing ‘The open brush should be thoroughly cleaned and dogreacod, with either an approved organic solvent, oF an eruision type ‘loaner. Hot degreasing solutions are preferred, Petrol, paraffin and similar materials are not recommended. ‘When using iquid degreasing agents, the brush should beheld downward to prevent the degreasing fluid, or water, being ‘rapped inthe throat ofthe brush, The degreasing process may bbe accelerated by use of an ultrasonic device. ‘The degreasing agent should be liberally used and worked wall Into the throat of the brush. water-based cleaning agents are used, the residues should be ‘completely removed by washing off in boling water. Then ‘allow the brush to dry. \When using a vapour degreasing method, the brush should be held inserted inthe vapour until al the grease and dirt has been | ‘emoved. Care must be taken to ensure thatthe rope above the serving is not immorsed in the vapour. corrosion proventives, not soluble in the above materials, have been used, the wire brush may be additionally dipped up to 80 % of its length fn @ hot solution of sodium hydroxide (400 g/t) then subsequently washed with hot water and dried ‘uickly. The time of immersion inthe sodium hydroxide solu tion should be carefully controlled so that any zinc coating is ‘not significantly attacked. CAUTION : During the cleaning and degreasing operations, the following precautions shall be taken : |) Great care must be token that degreasing is confined to the brush, and does not affect the rope beyond the brush. When using water-based elsaring agents, itis essontia to ensure that the agent is completely removed, that the brush is dried quickly, and that iis completely dry before pouting the molten metal. This is particulary important ‘whan Using sodium hydroxide solution, €) In all cases the time between cleaning and pouring should be a8 short 26 possible to minimize oxidation and ‘corrosion of tho rope. cen eaentcee eae 5.3 Hooking ISO 7595-1984 (E) 6 Pre-troatment of ropes of bright wires National regulations, of specific methods of socketing, may r6- ‘aire bright wires to be tinned, when socketed with molten metal. In certain conditions this may also be required to Improve adhesion between the wires and the socketing metal. In these cases the procedures given in annex A are recom mended 7. Positioning and alignment of brush, rope and socket [A seiting wire should be placed around the brush near is top ‘ond to draw the brush slightly together to form a shape approx- mating to, but sightly smaller than, the shape of the socket ‘basket, to prevent an appreciable length of the outermost wires ‘rom bearing against the wal of the socket when the socket is positioned over the brush. ‘The socket basket should be drawn over the brush unt the lands ofthe wires, or the bends in the hooked wire, are | mm to2 mmabove the basket of the socket, Altematively the wire ‘ends may be sightly below the top of the eocket, but in these ‘cases the rope just below the mouth of the socket should be ‘marked to Indicate any movement during subsequent opera- tions. “The wires should be eveniy distributed as far as possibie at the ‘0p of the socket basket Following the positioning of the brush, the rope should be clamped to a suitable support and the axes of the rope and sockst aligned. The rope below the socket should be straight {for at least 20 diameters, aftr which the rope may be alowed to bend but with a radius of atleast 80 rope diameters. The neck of the socket should then be sealed with » suitable heat-resistant material, to prevent passage of molten metal Care should be taken to ensure thatthe sealing material is not pushed into the gap between the socket and rope. If this occurs it wil prevent penetration of socketing metal through to the socket mouth, which could lead to catrosion and premature fatigue failure in service. When using sealing materials contain- ing water, care should be taken to ensure thet all moisture is driven off before starting to pour socketing metal. 8 Preheating and fluxing the socket After preparation and aligning the brush, rope and socket, the ‘sockot should be preheated to 120 to 350 °C depending on the ‘conditions and place of the socketing operation. ‘The preheat temperature should be monitored by a ther maometer, pyrometer, temperature-sensitve sticks or marks, of ‘other means suitable for ensuring that the temperature of the socket Is even and within the limits set. The preheat temperature should be achieved gradually by applying heat jvenly around the outer surface. Gare should be taken not to ‘overheat any part of the socket “The preheating lame must not be aBowed to come into contact withthe rope or wires10 7595-1984 (E) Particular care must be taken with ropes with synthetic cores to void overheating the socket or ope. Immediately the preheating temperature has been achieve, the socket may be luxed with powdered resin ora suitable ro: prietary compound, During this fixing all the wires in the ‘basket must be covered with fluxing compound. Pouring must commence immediately on reaching the preheating temperature. 9 Preparation of socketing metal and pouring “The socketing erucibie should be fed with ingots of new meta ‘and the pouring ladle should hold at least 20 % more metal ‘than requited t0 fil the socket basket. Heating of the crucible should be even, and the pouring temperature should be within the limits set by the specification (or supplier ofthe metal. Immediately prior to pouring, the molten metal should be stired to prevent separation of the constituents, and to ensure that an accurate temperature measurement can be obtained, ‘The dross should be removed from the surface of the molten metal, and the dey pouring ladle preheated by immersing it in the pot. The molten meta should be poured into one side ofthe | ‘socket basket to permit the escape of gates. Pouring should be ‘low and continuous until the basket i fl. If the molten metal solcifies too quickly, air bubbles may become entrapped or shrinkage holes may form which can be detriment ‘Therefore, when pouring larger sockets, in particular, i is ac sabe to extend the cooling period. This may be accomplished by using @ preheating device for some te ofter pouring. “Tapping the socket, whist the metals stil molten, may help to prevent entrapment of gases within the basket. ‘Stvinkage sometimes ocews in the metal at the top of the basket. In these cacee sulficont additional metal should be 1 Arnatey tight wites mite fared using the proce ‘poured to fil the depression. This should be caried out as the fnetal solide, and whore necessary the surtace metal should be rosiquified before pouring commences. ‘When the socket basket has cooled the seizing shall be re- ‘moved up to the mouth of the socket to facilitate inspection. “The socket must not be quenched in water at any stage during the cooling cele. [After the socket has cooled sufficiently @ suitable corrosion ‘preventive compound should be applied to the “cleaned” Tength af the rape taking care to cover all the exposed wires, and to seal the mouth ofthe socket 10 Socketing metals For guidance some examples of commonly used socketing ‘metals, together with their analyses and pouring instructions {te given in annex B. Attention is drawn tothe fact that certain socketing metals have bean developed for particular designs of socket. In case of doubt the metal manufacturer or sponsor should be consulted. 11. Quality contro! “The quality of the socketing may be assessed in one of the following ways: 2) by removing the cone after solidification, and visually inspecting it to ensure that itis satisfactory. If this method is ‘sed e478 should be taken to ensure that the orientation of the cone in the socket is the same before and after inspec: tion, This may be achieved by setting a mark: 'b)_ by visual inspection to ensure thatthe Socket metal has ‘completely filed the annulus between the rope and the ‘socket mouth, and thet the socket is properly Mec with socketing materia el a precautions lad down in anne A.A 1SO 7595-1984 (E) Annex B Examples of commonly used socketing metals B.1_ Lead-based socketing alloys Melting point: 20°C Pouring temperature = 380 + 10°C ky Tom ‘No. so 8 As p> jimpurhioe ‘Rina 1 [stew sBfaswies| | ro 2 ]70 w 80 | aww) — = remainder | 02 3 [20 wi | 90.110] 17.028 | 0307 [03:07 | wmincer | 02 | A005 % max. 210,05 % max 4 {810,05 % max Hor aos No, 1 ad 2 ott B.2_ Tinbased socketing alloys Matting point: 00°C Pouring temperature: 440 £ 10°C Porcaniage by mass of Teal inpurtion So 3 cu 7 [mows [Toews | sows | iwwa0 | ma~w.0 | wowwo | 65075 = J 1 50 sr B.3. Zinc socketing Making point: agec Pouring temperature : 4m + 20°C Aoy aeneae Ne. s é Bo) B.4. Zinc-based socketing alloys Melting point: 30°C Pouring temperature: 40 + 10°C amo Percentage by mass poate Ne. a oi mn | "hme Fe 06 . Ng 0.005 7 | seiose | s2t0r6 | remainder PY Son Sn 001SO 7595-1984 (E) Annex A Pretreatment of bright rope Before pouring, the wire brush of a bright rope may be tinned, in order to improve the adhesion between the wires and ssocketing meta, by the following procedure Al Fluxing ‘The cleaned wire brush should be dipped into a zine chloride solution for three quarters of the brush length. ‘A suitable zine ammonium chioride solution has @ composition 1s folows + Zine chloride (ZnCl) = 26 % Umi ‘ammonium chloride (NH,CI) 2.1 96 tonimn hhycrochlorie acid (HCI) 6,7 96 mim) water (4,0) = 58,8 % Um/m ensity (at 20 °C) 1.3 gle? Sipping time : ‘pproximately 1 min A2 Coating Immediately following fling the tit damp whole length of the ‘wire brush is slowsy immersed in molten tin solder (60 % Sn, 40% Pb) ata bath temperature of 280 + 10 °C [After tinning the wires should have @ tight adherent metal, ‘coating for about 66 % of the brush length. If his condltion is ‘not achloved the fluxing and metalic coating process should be repeated. Alternatively @ now brush may be formed. A3° Precautions ‘A.3.1 The fluxing solution and components ae strong skin initants. Care must be taken to ensure that they do not come into contact with the bare skin, A.3.2 The coating process must be caried out lowly and in such a way a8 to avoid splashing the hot metal.