The ceramic welding process was developed and originally designed for the situ repair of glass furnaces. In 1979 the technology was introduced to the United States as a method to repair coke oven walls in the steel industry. Since then the process has evolved to include other industries, primarily glass, aluminum, copper, foundry and cement.
PROCESS
Ceramic welding is applied during furnace operation by conveying a dry mixture of refractory aggregate and oxidizable particles together through speciallydesigned water-cooled lances. Many different lance sizes and configurations can be utilized to reach damaged areas inside the furnace or vessel.
The oxygen rich stream of powder contacts the hot furnace refactory lining where the metals ox idize during a highly exothermic reaction. Enough heat is produced (between 1600-2200C) by the combustion of the metals to melt the surface area of the refractory particles in the mixture as well as the surface of the damaged refractory lining. This reaction creates a long lasting durable bond.
Ceramic welding does in fact provide a very similar weld mass compared to the substrate refractory being restored. Difficult repairs are better facilitated with the use of Fuse Tech’s special water and air cooled furnace viewing e quipment which allows to technicians to view hard to see areas of interest. This equipment is capable of recording color or black and white video with audio.
Fuse Tech is also able to print on-site photographs of any area inside the furnace or vessel. This provides a useful tool to help gauge ceramic welding value by showing customers the before and after photos of the repairs.