Services we offer

Summary of services

Crack Repair Solutions

 

Providing solutions for chronic and/or severe cracking issues in all equipment. We provide the technical detail and support, and work with your preferred welding supplier to ensure you get the best repair outcome.

Don’t throw critical components such as steering arms and wheel motor frames away because they have cracks in them. We can repair them and ensure that they are safe and fit for extended service.

In order to get the job done right, sometimes it is necessary to have an expert welding supervisor on hand in order to advise on the repair and monitor the work done by the welding crew. And if you have no procedures and no welder competency tests, then sometimes your welding supervisor is all you can rely on.

Want to know the current state of your business in terms of how weld repairs are handled? We can provide an audit process so that you have a clear understanding of where your business is now, and what can be done to get you to the next level. WQMS can also audit your welding contractors to ensure that they are delivering the service you require.

Want to know the current state of your business in terms of how weld repairs are handled? We can provide an audit process so that you have a clear understanding of where your business is now, and what can be done to get you to the next level. WQMS can also audit your welding contractors to ensure that they are delivering the service you require.

WQMS provide a range of training and coaching services. Our half day welding awareness training will take your staff to the next level. We can also provide focussed training for your welders, teach them new techniques and upskill, and enable them to pass their welder competency test piece.

Chronic/Critical Crack Repair Solutions

Do you have problems with repeated cracking in a particular location on a machine, or fleet of equipment? A history of previous repairs, and short time before re-cracking develops, resulting in out-of-schedule repairs or very large cracks?

How are you managing repairs of cracking of critical components, which are highly stressed and/or have significant consequences of failure? A poor repair can have costly, or even fatal ramifications.

WQMS can provide an optimised repair solutions for chronic and/or severe cracking issues in all equipment, which restore your equipment to as close to original condition as possible or even with improved fatigue life. We provide the technical detail and comprehensive support, working with your preferred welding supplier to ensure you get the optimum repair outcome.

We welcome all the “too hard basket” problems, such as

  • Multiple prior repairs of the same area
  • Large complicated or multiple cracks in the same area
  • “Difficult to weld” materials such as castings and high strength steel
  • Restricted access repairs

As part of our technical service we also offer

  • Cracking metallurgical assessment, fractography and root cause analysis
  • Identification of extent of prior weld repairs
  • Material identification (composition and hardness) so the correct welding consumable and preheat can be selected

Reclamation of “Non-Repairable” Components

Why throw critical components such as steering arms and wheel motor frames away just because they have cracks in them? We can repair them and ensure that they are safe and fit for extended service. The “replace instead of repair” policy by the OEM is typically due to inherent risks associated with a poorly executed repair. WQMS undertakes a comprehensive metallurgical analysis of the material and causes of cracking. We then carry out weld repair procedure development and validation process to ensure that the component can be safely repaired. We then work with trusted welders of proven competence under a tightly controlled and supervised repair process in order to ensure there is 100% confidence in the final repair quality.

We manage this entire process, and only release the component if we are certain that the component is fit for service the intended overhaul schedule.  

This allows significant savings to be made by not having to buy new replacement components.

Examples of potential opportunities include

    • Truck Steering Arms
    • Wheel Motor Frames
    • Swing shafts  – splines and bearing journals

Welding Supervision and Inspection

In order to get the job done right, sometimes it is necessary to have an expert welding supervisor on hand in order to advise on the repair and monitor the work done by the welding crew. And if you have no procedures and no welder competency tests, then sometimes your welding supervisor is all you can rely on.

Supervision:

  • Perform welding supervision
  • Ensure correct joint tolerances are met and preheat is applied
  • Correct consumables are used and stored correctly
  • Repair Methodologies are followed
  • Ensure welding parameters are set appropriately to reduce the likelihood of defects
  • Conduct visual inspections
  • Supervision of critical/complex repairs
  • Shutdown welding supervision

Inspection:

  • Develop inspection & test plans

Welder Competency

Part of the barrier to achieving better quality weld repairs is the problem of ensuring that the welder is competent to carry out the required repair procedure. The reason for this is that traditional “Welder Qualification” testing is carried out using the generic welder qualification process from AS2980 or AS1554.1. This is typically a single sided overhead butt weld joint and/or a vertical up butt weld, in plate sections with perfect weld preparation.

However, the purpose of this test method is to “pre-qualify” welders for the welding of specific joint types when fabricating equipment. The problem with this “qualification” method is that it does not simulate a repair, which requires gouging first and various joint configurations, and also it does not accurately reflect a boilermakers skill to weld in a repair state in all positions. Furthermore, the test plate is usually performed using a backing bar, which is often not possible when carrying out crack repairs of box section structures. Also, the test is typically carried out in workshop conditions, with supervision and assistance to satisfactorily complete the test piece.  Most welders do not know how to read a welding procedure and are unfamiliar with best practice crack repair methodologies. The result of this is that “qualified” welders are often unable to achieve a quality in-situ weld repair.

That’s why we have developed a unique “welder competency” test piece that simulates a range of difficulty in actual repair requirements, which both assesses the welder’s skill and knowledge, and also “qualifies” them for the actual repair procedures. Welders will be classed from Level 1 to Level 3, with a “Master” level for welders with demonstrated expert ability who can do highly specialised repairs. We provide a register of Welder Competency records, that is freely accessible. This means that the right welder can be assigned to the job to ensure that the repair is done right.

We can also work with your welders to provide training and coaching to upskill them and ensure they pass the welder competency assessment, and have the necessary knowledge and skills to carry out effective weld repairs of equipment. We can also provide Dragline Boom welder training and assessment

Enquire to find out more.

Training and Coaching

WQMS provides a range of training and coaching services. Our half day welding awareness training will take your staff to the next level. We believe that education is the foundation of organisational change, and that improved awareness and knowledge combined with actionable steps and clear responsibilities leads to an empowered workforce.

We can also provide focussed training for your welders, teaching them essential welding theory (such as preheating), and practical skills for crack repairs (run-off tabs, sequencing, buttering, weld preparation geometry, weld finish requirements, etc). We can also provide coaching in order to enable welders to pass their welder competency test piece.

  • Half day training for all staff involved in the crack repair process to improve knowledge about welding and how to prevent cracking
  • Welder training of essential welding theory and crack repair techniques
  • Welder training to teach Welder training for advanced skills, such as TIG weld dressing, and temper bead welding.
  • Welder training for new technology and equipment (such as STT, plasma gouging, etc)
  • Coaching for welder competency assessments.

Audits

Want to know the current state of your site in terms of how weld repairs are handled? We can provide an audit process so that you have a clear understanding of where your business is now, what the “gap” is, and what the next steps are to get you to the next level. WQMS can also audit your welding contractors to ensure that they are delivering the service you require.

    • Site Audits – benchmark existing site processes, systems, equipment and staff knowledge to establish next steps for improvement
    • Welding Contractor Audits – ensure that welding contractors have suitable capability, equipment, and quality systems to deliver onsite and offsite repairs

Services Capabilities List

Crack Repair Solutions

  • Provision of custom repair solutions for chronic and critical cracking in all mining machinery
  • Cracking metallurgical assessment and root cause analysis
  • Identification of extent of prior weld repairs
  • Material identification (composition and hardness) so the correct welding consumable and preheat can be selected

Reclamation of “non-repairable” components

Safely repair and restore to fully serviceable condition, suitable for extended service life for normal overhaul schedules. Examples of potential opportunities include

  • Truck Steering Arms
  • Wheel Motor Frames
  • Swing shafts  – splines and bearing journals

Welding Supervision and Inspection

    • Supervision of critical/complex repairs
    • Shutdown welding supervision
    • 3rd Party inspection of weld repairs at hold points (crack removal, root run, capping runs, peening, final weld finish)

    Welder Competency

    • Welder competency assessment test kits
    • Free database for welder competency records
    • Welder training and coaching to upskill and pass the welder competency assessments
    • Dragline Boom welder training and assessment

    Training and Coaching

    • Half day training for all staff involved in the crack repair process to improve knowledge about welding and how to prevent cracking
    • Welder training to teach essential welding theory (such as preheating), and practical skills for crack repairs (run-off tabs, sequencing, buttering, weld preparation geometry, weld finish requirements, etc)
    • Welder training for advanced skills, such as TIG weld dressing, and temperbead welding.
    • Welder training for new technology and equipment (such as STT, plasma gouging, etc)

    Audits

    • Site Audits – benchmark existing site processes, systems, equipment and staff knowledge to establish next steps for improvement
    • Welding Contractor Audits – ensure that welding contractors have suitable capability, equipment, and quality systems to deliver onsite and offsite repairs

    Our vision

    The WQMS Concept

    Short description of this particular service.

    Our Services

    Short description of this particular service.

    Case Studies

    Short description of this particular service.

    Contact us

    I am interested in...