Ceramic welding is today’s most effective solution for industrial high temperature furnace repair and maintenance, as well as for damaged refractory repair. These advanced materials and techniques used help to extend the life of furnace refractories.
Because ceramic welding is a hot repair method, furnace repair work can be conducted while the furnace is hot – there is no need to cool down the surface nor shut down the furnace. The ability to perform this process during normal furnace operation is a key benefit to our customers as it helps to eliminate the potential loss of production.
Fuse Tech maintenance and repair solutions deliver long lasting furnace repair results – ensuring years of performance and durability.
HOT FACE WELDING AND COLD FACE WELDING
Fuse Tech provides two types of ceramic welding solutions: hot face welding and cold face welding. Hot face welding is used to repair damaged refractory material inside the furnace. Cold face welding is conducted on the outside of the furnace. Ceramic welding is a proven method for making hot repairs of industrial furnaces at operating temperatures.
SERVING THE WORLD’S MANUFACTURERS
The Fuse Tech team has the expertise and experience to provide ceramic welding maintenance and repair services to all sectors of the glass industry, as well as other industries such as steel, coking, aluminum, copper, cast iron and cement.
Ceramic welding by Fuse Tech helps extend the service life of furnace refractories used in the manufacturing of float glass, fibers, sodium silicate, and other special types of glass.
Ceramic welding is utilized by glass manufacturers and coke producers to prolong the life of their oven’s refractories with minimal production loss. Additionally, ceramic welding in the cement, aluminum, and copper processing industries is becoming more popular with the advent of Fuse Tech’s patent-pending technology allowing the attachment of stainless steel refractory anchors to the inside hot face of the kilns steel shell without shut down.
HOW CERAMIC WELDING WORKS
In general, ceramic welding is similar to the conventional welding of metals – a mixture of metallic compounds, a suitable welding material, and oxygen are sprayed into the affected area under pressure by a welding lance. With this process, metallic compounds oxidize in a highly exothermic reaction and the heat released creates a localized zone of extremely high temperatures. At these high temperatures (1600 – 2200º C) the welding material and the original refractory materials fuse together to produce an extremely strong bond. This procedure can be used to join existing refractory parts or to fill cracks or joints.
The original process of ceramic welding was developed in the late 1960s by a Belgian glass manufacturer. Today, ceramic welding technology has evolved to become a proven effective solution for a wide range of furnace and refractory repairs – even during high temperature furnace operation, without shut down.
PROPRIETARY CERAMIC WELD MATERIALS
The Fuse Tech team of welders and technicians complete their work with a range of lance types, process machines, and ceramic welding powders to accommodate a variety of furnace or refractory needs.
Fuse Tech carries a complete line of ceramic welding materials and powders including alumina-based, fire clay-based, crystalline silica-based, and high purity fused silica materials – these facilitate selecting the optimum material for different maintenance or repair applications. Learn more about Fuse Tech’s proprietary formulations and their applications here.
To discuss your industrial high temperature furnace ceramic welding maintenance or repair needs, please contact us.