AVANTECHNO portable boring and welding machines

5 STAGES

OF THE REPAIR PROCESS

Stage 1 — Access and preparation

Only the defective component is partially disassembled in order to provide access to the worn bore or surface requiring restoration. This approach is fundamental to the AVANTECHNO technology, as it eliminates the need for complete disassembly of large and complex assemblies.

In most applications, surrounding systems such as hydraulic, pneumatic, or mechanical connections remain intact, significantly reducing preparation time and minimizing secondary intervention on the machine.

The goal of this stage is to expose only the repair zone while preserving the overall structural and functional integrity of the equipment. This allows the repair process to be carried out directly on the installed component, without relocation to a workshop environment.

Stage 2 - Alignment and centering setup

A center alignment and centering system is installed on the component to ensure precise positioning of the boring bar relative to the worn geometry.

Depending on the configuration of the part, the system can be mounted on one or both sides of the opening, or simultaneously across multiple coaxial bores when required.

The system provides multi-axis adjustment of the boring bar, enabling precise centering based on reference surfaces, typically the least worn bore or other functional datum surfaces.

Alignment and centering are performed using precision measuring instruments to ensure correct positioning before machining begins. This step is critical for maintaining geometric accuracy throughout the repair process.

Stage 3 - Setup and rough boring

Support saddles are installed on the aligned structure and precisely adjusted to ensure stable positioning of the boring system. After final calibration, the alignment system is removed.

The machine is then mounted onto the saddles, forming a rigid and stable working setup that is independent of machine weight or external load factors. This ensures that machining accuracy is maintained throughout the operation.

Once the cutting tool is installed on the boring bar, rough boring is performed to remove ovality, deformation, and surface wear, or to approach the required final diameter.

This stage restores the primary geometry of the bore and prepares the surface for the subsequent material restoration process.

Stage 4 - Automated welding process

For material restoration, the boring bar is replaced with a welding shaft equipped with a welding head connected to a semi-automatic welding unit.

Material build-up is performed in automated mode, where the system controls rotation and ensures controlled deposition of weld layers onto the worn surface.

A shielding gas mixture of Argon (80%) and CO₂ (20%) is typically used to ensure stable welding conditions and consistent material deposition.

The resulting welded layer achieves a surface hardness of approximately 25–30 HRC, depending on welding parameters such as current and gas composition.

This stage restores material volume on the worn area and prepares the component for final precision machining.

Stage 5 - Finishing and verification

After the welding process, the boring bar is reinstalled for final machining operations.

A rough finishing pass is performed, followed by precise measurement of the actual diameter using a digital indicator. Based on the measurement results, the cutting tool is adjusted to achieve the required final tolerances.

Final boring is then carried out to restore the component to its nominal dimensions with high geometric accuracy.

After completion of machining, the system is removed and the repaired area is cleaned from welding and machining residues.

The component is then ready for inspection and return to operational service.

Stage 1

The technology requires disassembly ONLY of defective part in order to get access to reconditioned opening.

Stage 2

The next stage is mounting (with welding or any other applicable way) of center alignment kit. The kit, depending on the type and layout of reconditioned part, is mounted either on both sides of the opening, or in case of simultaneous reconditioning of several coaxial openings, on the sides of those openings.

By virtue of its design, center alignment kit allows 3-axle adjustment of boring bar position, which passes through thee whole width of reconditioned surface. Boring bar alignment is performed with special measuring devices basing on the least worn-out opening or other basis surfaces.

Stage 3

Saddles are put at the aligned boring bar. After fine-tuning of bolts and mounts, saddles are being welded to the reconditioned part. Then the center alignment kit needs to be removed.

The machine is firmly mounted on one of the saddles. Machine’s weight does not affect the accuracy of executed technological operations.

After installing the cutting tool into the boring bar, the opening is being bored until the ovality is eliminated or until reaching the required diameter.

Stage 4

To perform welding thee boring bar is being replaced with a special dielectric shaft with welding head. The shaft is being connected to a semiautomatic welding machine with a special cable.

The gas mix used consists of 80% Argon and 20% CO2 (carbon dioxide). The mix is feeded to welding machine either directly through a pressure reducer or via a gas mixer from two separate bottles of Ar and CO2.

Surfacing of a required number of layers of metal is carried out in automatic mode with a semiautomatic welder while the machine ensures rotation and feeding of welding head. The firmness of welded surface is 25-30 HRC depending on welding current and gas mixture.

Stage 5

After the surfacing and removing of welding shaft, the boring bar is put back. After the rough boring an actual diameter is measured and the cutting tool is adjusted to the required diameter with a special digital indicator.

Then the finish boring is performed. After the control measuring, the machine is dismounted and the part is cleaned from welding marks.

The standard kit includes everything required for the operations except for welding machine and gas equipment (bottles, mixers, reducers). We recommend using of well-known brands 3-phase semiautomatic welding machines, but theoretically any semiautomatic welder may be used as long as it meets the requirements of CDF=100% at welding current 100A and stable continuous feeding of welding wire without jamming.

Advantages

of technology and equipment

by AVANTECHNO

1. UP TO 90% TIME AND COST SAVING

Significant reduction of labor, material and financial costs for repair and reconditioning works:

no need for full dismounting and transportation of defective assemblies and units to a repair shop, reduction or complete elimination of transportation costs which constitute the largest cost proportion of the estimate for the repair of large-sized machinery and equipment
significant reduction of the total repair time and of machinery downtimes
reduced involvement of repair staff, optimized human resource distribution

2. SIMPLE OPERATION AND SUPPORT

training in the operation of the complex and in state-of-the-art machinery repair technology
fast supply of spare parts and consumables
engineering and consulting support

3. RELIABLE AND FAILURE-FREE OPERATION

place of origin: European Union
warranty period: 24 months
consistency of operation parameters
consistency of operation parameters
possibility of operation under extreme conditions

UP TO 90% TIME AND COST SAVING

Significant reduction of labor, material and financial costs for repair and reconditioning works:

no need for full dismounting and transportation of defective assemblies and units to a repair shop, reduction or complete elimination of transportation costs which constitute the largest cost proportion of the estimate for the repair of large-sized machinery and equipment
significant reduction of the total repair time and of machinery downtimes
reduced involvement of repair staff, optimized human resource distribution

SIMPLE OPERATION AND SUPPORT

training in the operation of the complex and in state-of-the-art machinery repair technology
fast supply of spare parts and consumables
engineering and consulting support