Weldable Insert Welding Instructions

• Welding 42CrMoA (a chromium-molybdenum alloy steel, similar to AISI 4140) inserts requires specific procedures due to its low weldability and susceptibility to cracking. This process requires strict preheating and controlled cooling, and should only be performed by competent and qualified welders using low-hydrogen methods. If correct welding, assembly, or handling procedures are not followed, the load could detach from the workpiece. Please follow these instructions carefully. Failure to follow these instructions can result in severe injury or death.
• Review and understand all instructions before welding or using these weldable inserts.
• Always pair the weldable insert with the proper size plate.
• The plate material to which the welded insert is welded must be strong enough and properly designed to handle the maximum expected loads in all operating positions. Factors like material type, thickness, and unsupported length should be reviewed by a qualified professional. Take extreme caution to calculate the effect of sagging in the load. When in doubt, an engineer should be consulted to ensure end-user safety.
• Do not attempt to modify, repair, or reshape either the weldable insert or the PlateMate Swivel Hoist Ring by heating, welding, grinding, or bending. Grinding of excess weld material flush with the plate at the end of the welding process is required and permitted.

Safety and Expertise Warning

Welding high-strength alloy steels in demanding applications like trench cover plates requires specialized knowledge of metallurgy and welding procedures to prevent catastrophic failure, cracking, and potential injury. An American Welding Society certified welder should perform the welding on these parts. It is the responsibility of the company who employs the welder to determine whether the welder is trained and competent to perform these tasks.

Welding Procedure for 42CrMoA Inserts

The goal is to prevent rapid cooling in the heat-affected zone (HAZ), which can lead to a brittle microstructure and cracking. A slow cooling process is critical to the integrity of the final weld.

Materials and Equipment

• Welding Process: Shielded Metal Arc Welding (SMAW/Stick) or Gas Metal Arc Welding (GMAW/MIG) are the only processes recommended
• Filler Metal: Use low-hydrogen electrodes that match the strength of the lower-strength material. Only use following:
• SMAW: E7018 electrodes
• GMAW: E70S-6 weld wire
• Preheating Equipment: Torches, electric blankets, or induction heaters should be used for uniform heating.
• Temperature Monitoring: Use temperature crayons or infrared thermometer to ensure precise preheat and interpass temperatures are met and maintained.
• Welding Fixture: The use of a weld fixture to hold the insert square and protect the threads during welding is recommended. Ask your salesperson for more information.

Finishing

• IMPORTANT: Grind the final weld on the top surface flush with the plate surface to ensure attached components sit properly. The PlateMate Swivel Lifting Ring must seat flush to the plate. Excess weld material that has not been ground off will cause the Lifting Ring to seat improperly. This can cause accidents the could result in serious injury of death.
• Always visually inspect the weld for defects.