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BORTECH BoreClad

MODELS BC01, BC02 & BC03

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The BoreClad System


What Is The BoreClad?
Dramatically Faster Than Hand Welding Consistent High-Quality Welds In-House Cladding Controls Cost & Delivery Times Reduces Operator Exposure To Hexavalent Chromium
The BoreClad is an integrated welding system that rotates the work piece while applying the highest quality weld overlay. An adjustable axial torch feed system is provided which uses Bortechs step process. The water cooled welding torch steps back once per revolution of the part giving an extremely uniform weld over the entire length of the bore. Any commercially available alloy can be used, such as Inconel, Hastelloy, Monel or Stainless Steel. Flange faces and gasket surfaces can also be automatically clad with the optional face torch.

Why Choose The BoreClad?

Control the high costs of weld overlay If you currently subcontract your cladding, BoreClad is an aordable way to bring the cladding operation in house, giving more control of cost. Have direct control over schedule Dont rely on a subcontractor to keep your tight schedule intact. Avoid costly delays in nal product delivery. Maintain the highest quality of weld overlay The BoreClad is typically twice as fast as TIG overlay systems, while maintaining equivalent functional weld quality. Make the highest quality void free weld, while maintaining minimal weld dilution. Parts can be automatically welded non-stop. Avoid exposing your welder to hexavalent chromium BoreClad keeps the operator away from the work piece, avoiding potential exposure to hexavalent chromium. Point elimination of welding fumes is easily achieved. Remove the hidden costs of weld overlay when using a subcontractor Avoid the numerous hidden costs of weld overlay, such as shipping charges, logistics, additional paperwork, procedure documentation, rework, etc. More economical than other weld overlay systems without sacricing quality The BoreClad is an aordable alternative to other higher priced cladding systems. Lay ve pounds of metal per hour hour after hour with the highest quality results. The BoreClad can reduce weld times by as much as 75% over hand welding, freeing your skilled welder for other tasks. Clad smaller bores than possible with other systems The BoreClad is capable of cladding bores as small as 1.2 inches in diameter. Bores that are too small to be welded with other cladding systems or by hand can easily be welded on the BoreClad
Source capture welding fumes.

The #00 Small Bore Torch allows cladding of bores as small as 1.2 inches (31mm).

Use your existing Constant Voltage power supply There is no need to purchase another weld power supply for your shop, use your existing CV power supply. The BoreClad can interface with most CV power supplies that are remote interconnect capable, and have a 200 Amp, 100% duty cycle. Weld transfer modes include GMAW-S (short circuit), GMAW-P (pulse waveform), and FCAW-G (gas shielded ux core).

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The BoreClad model BC01 is the smallest and most economical machine in the BoreClad family. This cladding machine is recommended for applying a weld overlay in bores from 1.2 to 10 inches in diameter. Flange faces up to 13.75 inches in diameter can also be clad with the optional face torch accessory. An encoder with digital readout is included that indicates axial torch position within the work piece. The Model BC01 is available in 3 stroke lengths, 18, 24 and 36 inches. Stroke length equals maximum part length.

MODEL BC01

36 inch stroke length shown

Minimum Bore Diameter Maximum Bore Diameter Maximum Flange Diameter Maximum Part Weight Available Stroke Lengths (maximum part length) Amperage at 100% Duty Cycle Torch Type Wire Size

1.2 (with optional torch) 11.5 (10 recommended maximum) 13.75 150 lb. 18, 24 & 36 200 Amp Water Cooled .035 or .045

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The BoreClad model BC02 is the mid size machine in the BoreClad family. This machine is used for cladding larger and heavier parts than can be handled with the Model BC01. The Model BC02 is recommended for applying a weld overlay in bores from 2 to 18 inches in diameter. Flange faces up to 24 inches in diameter can also be clad with the optional face torch accessory.

MODEL BC02

ease the loading and centering of larger heavier parts. The table tilt feature is a powered function and operates by push button from the Bortech control system.

An encoder with digital readout is included that indicates axial torch position within the work piece. The Model BC02 is available in 3 stroke lengths, 18, 24 and 36 inches. Stroke length equals maximum part length. The Model BC02 features a table that tilts to the horizontal position to help

36 inch stroke length shown

Loading position

Minimum Bore Diameter Maximum Bore Diameter Maximum Flange Diameter Maximum Part Weight Available Stroke Lengths (maximum part length) Amperage at 100% Duty Cycle Torch Type Wire Size

2 18 24 300 lb. 18, 24 & 36 200 Amp Water Cooled .035 or .045

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The BoreClad model BC03 is the largest machine in the BoreClad family. This machine is used for cladding larger and heavier parts than can be handled with the Models BC01 or BC02. The Model BC03 is recommended for applying a weld overlay in bores up to 22 inches in diameter. Flange faces up to 32 inches in diameter can also be clad with the optional face torch accessory.

MODEL BC03
The Model BC03 features a table that tilts to the horizontal position to help ease the loading and centering of larger heavier parts. The table tilt feature is a powered function and operates by push button from the Bortech control system.

An encoder with digital readout is included that indicates axial torch position within the work piece. The Model BC03 is available in 4 stroke lengths, 18, 24, 36 and 48 inches. Stroke length equals maximum part length.

48 inch stroke length shown

Loading position

Minimum Bore Diameter Maximum Bore Diameter Maximum Flange Diameter Maximum Part Weight Available Stroke Lengths (maximum part length) Amperage at 100% Duty Cycle Torch Type Wire Size

2 22 32 550 lb. 18, 24, 36 & 48 200 Amp Water Cooled .035 or .045

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OPTIONAL TORCHES
FACE TORCH
Any BoreClad can be outtted with an optional face torch. This torch is used for automatically cladding ange faces and gasket surfaces.

Increase the versatility of your BoreClad by adding the optional torches shown below.

The BoreClad Model BC01 can be outtted with the optional #00 Small Bore Torch. The #00 Torch is the smallest welding torch available for the BoreClad, and is capable of cladding bores as small as 1.2 inches (31mm) in pre-welded diameter. Torch length is 24 inches. This welding torch is water cooled, to help extend run times.

#00 SMALL BORE OD TORCH

The Outside Diameter Torch (OD Torch) is an optional accessory that allows a weld overlay to be made on the outside diameter of a part. OD Torches are non stock, and are custom built for specic applications. Contact Bortech Corporation for details on this torch.

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The Bortech Model 1202 is ideal for weld cladding the largest and heaviest parts. A highly versatile machine, the Model 1202 can be quickly and easily congured to weld overlay bores, outside diameters, ange faces, and conical surfaces up to 12 feet (3660mm) in diameter.

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Advantages:

MODEL 1202

There is no need to lift or mount a heavy part on a weld positioner, enhancing personnel safety in your shop. The part being welded rests safely on the shop oor. There is no risk of a part falling and causing injury. Since the part is not rotating, pre heat can be applied with an induction heater or heat blanket instead of an open ame, increasing safety in your shop. A consistent, uniform preheat and interpass temperature can more easily be maintained. Thermocouples can be attached to the part to monitor temperature. Bores that have a non symmetrical exterior can be easily clad since the Model 1202 centers on the bore, and does not reference the exterior of the part. Auto Skip and PIE Mode functions are available on the Model 1202, allowing the machine to automatically weld or skip a segment of the part. The Model 1202 uses the GMAW weld process with wires up to .062 inch diameter, allowing deposition rates of up to 12 pounds per hour. Solid or tubular wires can be used. There is no need to purchase a special weld power supply. Use your existing constant voltage power supply. Minimal weld dilutions can be maintained, often lower than Sub-Arc systems. The Model 1202 can be used for repair applications in addition to weld cladding. The Model 1202 is portable and can be used in the eld. Keep your welder away from hazardous fumes and smoke. Drastically reduce weld times over hand welding, while simultaneously increasing quality.

The Bortech Model 1202 rotates the torch around the work piece, eliminating the need to rotate the part being welded!

Typical applications include:


Rock crusher repairs Large valve seats Idler wheels Rolling mill chocks Cladding large nozzles or manways Cladding small vessels

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Do You Have A Repetitive Circular Welding Application?


Any Bortech welding machine can be converted to a production line welder. If you are making circular welds in your fabrication process, a Bortech machine may be the perfect solution. Dont waste money on a complicated robot that has more features and capabilities than you will ever need. Robots require programming every time there is a change in parameters. Bortech machines are simply adjusted by your shop personnel. Bortech machines can make internal or external circular welds in your assembly process. Linear welds are also possible, either internal or external. If a standard Bortech machine does not t your needs, Bortech can modify an existing machine design, or engineer a new machine from the ground up. Various levels of automation are possible. Let Bortech put its extensive knowledge of bore welding to work for you in your manufacturing environment.

A custom xture was designed specically for this repetitive application.

This customized Model BC01 allows the customer to fabricate 500 consistently high-quality assemblies in a 10-hour shift.

Bortech Corporation 66 Victoria Street Keene, New Hampshire 03431 Toll Free: 888-265-1202 o International: 603-358-4030 o Fax: 603-358-4007 Email: info@bortech.com o www.bortech.com
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