Mining equipment often requires regular maintenance and repair of various steel structures. Customers often request equipment representatives to help technically supervise critical repairs to insure they are done properly. The following example shows the typical field assignments Mr. Spadoni has performed in various locations such as the US, China, and Canada...

Oil Sands Shovel Canada


Dipper Field Repair-Canada

When mining equipment breaks down it costs the mine millions of dollars. In this situation a large crack had developed on the underside of the dipper lug. If not repaired right away the crack would have most likely torn off the lug and caused further damage. The root cause of the cracking initiation was also traced back to the plant and the problem was solved before future orders would be effected.
Crack located in 5´ lug plate. Required thorough excavation and proper weld repair.


MPT revealed cracking on bottom side of hoist lug.


Truck Frame Field Repair Supervision-China

Truck Frame 2´ Thick Plate Truck Frame

Damaged Plate Section Removed. Crawler Frame

This was a catastrophic failure where the Crawler Frame of this shovel had cracked and broken free from the truck frame. A large section of the truck frame was damaged and had to be replaced as shown. The new plate material was prepared, welded in-place using the proper welding parameters, and inspected using Liquid Penetrant.


SHOP PROJECTS Today manufacturing facilities require flexible individuals who can work well with personnel on the floor as well as use their computer skills to report and present information on their projects to upper management. Mr. Spadoni has a strong hands on background as well as the necessary computer skills to fit in at both ends of the spectrum. Following are some examples of projects that Mr. Spadoni has been involved with over the past few years exercising those skills.


Gear Case Inspection & Rebuild Project
Large gear cases are often used on mining equipment in order to move the massive buckets filled with material. At one point several gear cases began failing in service. In order to find the root cause of the failures each gear case had to be disassembled, the gears thoroughly inspected dimensionally and Non Destructively using Wet Magnetic Particle Inspection

Gear tooth under MPT black light. Components were removed and inspected using Wet MPT. This revealed surface cracks in the tooth surface.


Pipe Fabrication Project
When a project was received to weld flanges on 300 pieces of pipe that were 60 feet long we stood up to the challenge. A complete production line had to be made to move the pipe from one station to the next while insuring that each weld was X-Ray Quality. After Welding the pipe had to be blasted, lined with rubber, and painted.
Welders worked simultaneously on each end while the pipe was rotated. Flanges were welded on by using GMAW .035´ for the root pass and FCAW for the fill.


Fatigue Life Improvement of Welds
There are various ways to help improve the fatigue life of welds including Grinding, Peening, and Tig Dressing. Some methods are more manufacturing friendly than others, however there was not enough specific data available on the which of those methods will be better or worse for improving the fatigue life of a weld. Therefore a project was created to test several methods of improvement and choose the most shop friendly method that still produced a quality weld with enhanced fatigue life«. Next Page

One method is to grind the toes of the welds with a cone shaped stone grinder. The major problem with this method is that grinding is very unfriendly to the operator and can cause serious long term medical problems.


Fatigue Life Improvement of Welds-Continued
Several methods of fatigue enhancement were tested by creating welded coupons for each method, cutting them into several samples, and then loading them cyclically in a tensile tester.


Welded Tee Joint Coupon cut into 2´ wide samples as shown.


The testing took many hours to complete before a conclusion could be made. It was a good investment in that it save several hours of production time and medical costs.


Cable Rope Drum Rebuild Project
Steel cable wraps around the drum following these grooves.

A type of centerline Cracking/Tearing constantly failed the test blocks.

Large cylindrical drums are used to move large diameter cable on mining equipment. The constant movement causes a great wear in the rope grooves. Therefore when the drums are built the surface layer is heat treated to help retard the wear. Eventually the drums will have to be resurfaced with a hardened layer of material. Therefore a projects was started to come up with a welding electrode and procedure to perform this type of heat treatable weld buildup. Finally through the efforts of good electrode suppliers and engineers a heat treatable electrode was developed.

Micro of Tear


Damien Avenue Bridge Project
This large bridge was build for the Chicago area and uses two large arches as seen in the photo. The arches are made from 44´ diameter sections of pipe which had to be welded together to meet AWS Bridge code requirements. The job was audited by city and customer inspectors.
Large diameter pipe segments welded together make up the arch of the bridge.


Weld Parameters Issue

When a historical amount of X-Rays were being rejected for large amounts of Tungsten inclusions, the root cause and solution had to be found. Dozens of variables presented themselves but with a close collaboration with the welders the source of the problems were found to be both technique and equipment related.
Several X-Ray Quality welds on large Aluminum Heat Exchanger made to ASME Section VIII and IX.

Using sophisticated software the output wave of the machine could be analyzed to find that several voltage and current spikes were being experienced in older machines.

Welding/Manufacturing Engineer: Komatsu America, Chart Industries
EXPERIENCE Komatsu America, Peoria, IL.-Currently Employed Senior Welding Engineer for mining equipment manufacturer. Conduct throughput and critical path analysis of frame welding process. Responsible for updating/maintaining all work instructions for we ld processes. Member of ISO 9001 implementation team and lead auditor. Develop training program for welders to reduce rework and increase efficiency. Chart Heat Exchangers, La Crosse WI. Nov. 2004-Jan 2006 Welding Engineer for company manufacturing large industrial heat exchangers for the petrochemical and air separation industries. Develop, maintain, and control all manufacturing work instructions/procedures. Facilitate welder qualification testing for ASME IX and EN287 requirements. Approve mechanical weld tests (PQRs) to insure compliance with ASME IX and EN288. Adminster and track welder qualifications to insure continuity/prolongation of certificates. Developed training program which led to a significant reduction in rework.

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Weld Engineer/Supervisor: Bucyrus International
Bucyrus Intl, Milwaukee WI. 1998-2004 Quality Assurance Supervisor Responsible for Fab and Weld Inspection program, includes 5 inspectors / technicians. Provide technical assistance to floor personnel in welding, NDT, and problem solving. Perform external supplier audits and in-house process audits to insure process control. Monitor and publish quality reject system to help insure continuous improvement and reduction in scrap and rework instances. Welding Engineer Created SPC system to monitor weld defects leading to a 40% reduction in rework. Facilitated team efforts to reduce plate burning defects by over 85%. Project Manager of rebuild and assembly program for heavy equipment gear case. Coordinated project to test different methods for improving the fatigue life of welds. Write welding procedures according to company weld standards and AWS D1.1 code.

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Engineer: Bendtec Inc., Duluth MN. September, 1997- October 1998  Qualify welding procedures to ASME IX, API 1104, and AWS D1.1 for various processes including Submerged Arc Welding (SAW), Shielded Metal Arc Welding (SMAW), Gas Tungsten Arc Welding (TIG), and Gas Metal Arc Welding (MIG).  Studied carbon steel microstructures and mechanical properties of metals. Welder/Fitter for Spectrum Steel, Hyrum, Utah March 1995-September 1995  Used Flux Cored Arc Welding (FCAW) and Shielded Metal Arc Welding processes to fabricate structural steel to AWS D1.1.  Operated radial drill press, cutoff saw, and metal shearing machine. Instructor Assistant at Glendale College, Glendale, CA. September 1991-June 1993  Assisted with training of new students on setting up work station and machine.  Also performed a variety of heat treatments on various types of steels, shop equipment repairs, and maintenance of facilities.


B.S. in Welding Engineering Technology, with a dual major in Business, Utah State 
University, June 7, 1997. A.S. Welding Technology, Glendale College, Glendale Ca., June 1993.



Training: ISO9000 auditing, Total Quality Management, Product Development, Failure Mode and Effects Analysis (FMEA), MSHA(Mine Safety and Hazard Admin.) Microsoft Word, Excel, Power Point, Autocad, BAAN, E-Matrix, ect... 8 Year Member of American Welding Society(AWS) Completed 2 year Welder Certificate Program, Glendale College-1993. Certified in First Aid and CPR.


Feel free to contact me at the following email address«
Email: edmfs2000@yahoo.com