Benefits of Cold Face Welding
Coldface welding makes industrial and glass furnaces more energy efficient. The cold face welding seals the joints on the exterior of the furnace enabling it to be more airtight and therefore retaining heat and helping to reduce heat loss.
Cold face welding ensures the gas-tight sealing of expansion joints after completion of the furnace heat-up. Ceramic welding is a superior method of sealing joints as it provides a reliable and long-lasting gas-tight seal – is an essential factor in efforts to reduce furnace NOx emissions.
Cold face welds, repair, and maintenance can be conducted with minimal disruption to your furnace performance as no downtime will occur.
Cold Face Welding Applications
Coldface welding is primarily used when a new furnace is installed and commissioned – and heated initially. Additionally, cold face welding procedures are utilized when an old furnace has been shut down to a cold state and re-started to hot.
An example of a common cold face welding application includes joint sealing between crown and superstructure sidewall. Additionally, the joints between the skewbacks and the sidewall, or between the tuckstones and the tank blocks, are typical areas where cold face ceramic welding is used for sealing.
The Coldface Weld Process
Fuse Tech’s experts use a range of different lance sizes and combinations to reach all expansion joints from outside. This approach to cold face welding allows us to repair difficult to reach areas such as between buckstays and between port necks or tank blocks.
In the welding process, the stream of welding powder enriched with oxygen comes into contact with the hot refractory surface causing the metallic components to oxidize in a highly exothermic reaction. The existing heat development (over 2000° C) melts the refractory material with our welding powder, which provides a close seal and ensures gas-tight expansion joints.
Fuse Tech cold face welding delivers long-lasting welds between the brick/masonry furnace or boiler materials.
Servicing all industrial furnace types
With years of cold face welding experience and expertise, Fuse Tech provides cold face welding services to the glass industry (float, containers, fibre, sodium silicate, special glasses) and other industries such as steel, coking, aluminum, copper, cast iron and cement.
Fuse Tech is the leader in furnace repair and ceramic solutions
A range of ceramic solutions are available for cold face weld repairs and maintenance, depending on the location of the damaged area of the furnace. Learn about our full line of proprietary and patented ceramic weld materials available for applications such as the repair of cement kiln nose rings, repair of glass furnaces, repair of coke oven jambs, and the repair of glass furnaces and coke ovens.