Mavrix Welding Automation Inc. has redesigned its dual-torch shredder disc rebuild system with an improved mounting system and open carriage design that it reports will reduce installation time to 30 minutes or less. The dual-torch system can apply 50 lbs. of weld metal per hour, which the supplier said shortens downtime significantly shortening downtime, as well as the frequency of maintenance events and the cost-per-ton of scrap or recycled material.

Mavrix Welding Automation’s dual-torch hard-surfacing system has a new carriage design and single control pendant, for faster installation and easier operation.

The dual-torch disc rebuild system includes two weld carriages that support the weld arm and adjustable open arc torches, wire feeders, and 60-lb. coils of wire. The carriage with the new opening design allows the main beam and legs to be installed first and the carriages second, significantly reducing the weight of the system and making installation easier.

Now, Mavrix has consolidated the controls into a single hand-held pendant that allows operators to be mobile while maintaining control. With the pendant, operators are free to maintain a safe distance from welding fumes while controlling voltage, amperage, rotation speed, and circumferential step-over. With the remote start/stop the operator can pause at any time to inspect the work, and then restart without out concern for “wire whiskers” because a built-in burn-back circuit eliminates the welding wire sticking to the workpiece.

The disc rebuild system matches well with the Stoody 110MC, a modified high-chromium manganese steel metal-cored wire designed for parts subject to severe impact loading. This wire allows the system to be used in a single wire welding solution; there is no need to build up with one product and then switch to a hard-facing wire. A single wire solution reduces stocking requirements and eliminates concern with residual hard-facing material when returning for subsequent build events. Stoody 110MC appeals to welders, and offers low slag, goes down softly, and work hardens to 55 HRC.

Mavrix is a custom builder of hard-facing and metal build-up systems that they can be integrated with hammer-type shredders with disc rotors, including systems build by from Metso-Texas Shredder, Riverside Engineering, Newell, TSC, Wendt, and American Pulverizer. It has installed systems nationwide, and works with many manufacturers to ensure its products fit precisely to the shredder system.