Repairing of Cast Steel Crank Arms for the Power Generation Industry

repair_cast_steel_largeIn line with the work we specialize in, Denver Machine Shop was hired to rebuild the crank arms shown to the right for a customer in the power generation industry. Rebuilding these parts cost 1/3 of the price of making new parts, and can be completed in a fraction of the time of ordering new OEM parts. Our AWS certified welders performed a weld build-up of the face and damaged parts of the arms using cast steel. This hard surface weld was done with our advanced sub arc welder. Then, employing our CNC horizontal boring machine (equipped with a 92″ x 76″ window) two bores were made in each arm, in line with one other. The finished bores were 8″ and 10″ in diameter. Parts of the face were also machined, and a tolerance of ±0.0005″ was maintained throughout. The arms were sandblasted and cleaned, and the outer surfaces painted to customer specifications. A 100% dimensional inspection was carried out to confirm accuracy.

The finished length of each part was 70 in. each with a weight of over 600 lbs. Turnaround time for this project was 5 days, on a 24 hour schedule to ensure timely startup of the plant. Denver Machine Shop specializes in repairing, re-building, and manufacturing heavy machinery at affordable prices with minimal downtime. For more information about this cast steel crank arm rebuild or the other services we offer please see the table below or contact us directly.

Highlights of this Crank Arms Rebuild Project:

Product Description Rebuild of two crank arms with two bores each in line with each other
Capabilities Applied/Processes
Primary: 
Inspection 
Weld Build Up – on face and damaged places 
Boring 
Face Machining
Secondary: 
Sand Blasted 
Cleaned 
Painted – On Outer Surfaces
Equipment Used to Manufacture Part Sub-Arc Welder 
CNC Horizontal Boring Machine with a 92″ x 76″ Window
Overall Part Dimensions Product Length: 70″ 
Product Diameter: Ø 8″ Bore and Ø 12″ Bore 
600 lbs.
Tightest Tolerances ± 0.0005″
Material Used Cast Steel / hard surface welding
Material Finish Machined Finish
In process testing/inspection performed 100% Dimensional Inspection
Industry for Use Power Plant
Volume 1
Delivery/Turnaround Time 5 Days – 24/7 Operation to ensure timely start-up of plant
Delivery Location Colorado
Standards Met Customer Specifications, 2D CAD Drawing
Product Name Crank Arms
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