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Table of Contents
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Why Piston Repair is Critical in the Mining Sector
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Case Study: Successful Piston Repair Using LoTherme 468
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How LoTherme 468 Welding Electrodes Work for Piston Repair
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How D&H Sécheron Helps with Piston Repair
In the mining industry, even a short equipment breakdown means lost productivity and high costs, especially when critical parts like piston crowns wear out. Instead of costly replacements, a smarter and more economical approach is piston repair using high-performance welding electrodes like LoTherme 468. Designed with advanced welding electrode specifications like high strength, precision, and durability, LoTherme 468 allows restoring damaged pistons quickly and reliably, helping mining companies cut repair costs, extend equipment lifespan, and reduce operational downtime.
This blog highlights how D&H Sécheron restored a worn piston crown using LoTherme 468, demonstrating its effectiveness in demanding field conditions.
Why Piston Repair is Critical in the Mining Industry
The mining industry is one of the most demanding sectors, where heavy machinery runs around the clock to extract and transport valuable minerals. In India, the mining sector is key in powering industries like steel, power, cement, and construction.
Among the critical components in mining equipment are piston crowns, parts that face extreme heat and pressure during engine operations. Over time, this harsh environment causes the piston crowns to crack, wear out, or erode, affecting engine performance and leading to machine failure.
So, Why Repairing Pistons Makes More Sense Than Replacing Them
According to a report by ABB India, even an hour of unplanned downtime in the mining sector can cost up to ₹7 million. With such high stakes, repairing critical components like piston crowns is often more practical and economical than a complete replacement. Here’s why piston repair is the smarter choice:
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Cost Savings: Equipment rebuilds can save up to 40–60% compared to buying new equipment
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Faster Turnaround: While sourcing new pistons takes time, LoTherme 468 welding electrodes enable quick, reliable repairs, minimising operational delays
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Extended Equipment Life: Well-executed repairs restore piston performance and extend overall machinery lifespan.
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Minimal Downtime: Faster on-site mining equipment repair means quicker return to operations, reducing productivity losses.
By choosing repair over replacement, companies in the mining sector save time, reduce costs and ensure their machines run longer and more efficiently.
Case Study: Successful Piston Repair Using LoTherme 468
A leading mining industry faced repeated piston crown failures in its heavy-duty excavators. Previous repair attempts using L&T 680 CGS electrodes failed, causing frequent breakdowns and costly downtime.
The Challenge:
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Frequent piston crown failures
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Ineffective past repairs
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High downtime and replacement costs
The Solution:
To address the issue, D&H Sécheron used 3.15mm LoTherme 468 at 90–100 amps with 150°C preheating. This high-strength, crack-resistant electrode ensured a durable on-site repair.
The Result:
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Over 70% reduction in downtime
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No cracking under extreme stress
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Cost-effective, reliable piston restoration
This successful application demonstrates the effectiveness of LoTherme 468 for high-performance mining equipment repair.
How LoTherme 468 Welding Electrodes Work for Piston Repair
LoTherme 468 is a rutile-coated stainless steel electrode designed for tough repairs in mining equipment. With high tensile strength (up to 830 MPa), 23% elongation, and crack-resistant welds, it restores piston crowns to near-original performance. Its low heat input prevents distortion, while smooth, spatter-free welds resist wear and withstand extreme pressure, heat, and corrosion, making it a reliable, long-lasting solution for critical piston repairs.
How D&H Sécheron Helps with Piston Repair
When it comes to heavy-duty welding solutions, you need a partner who understands the risks and responds with expertise. Backed by a team of welding specialists, D&H Sécheron provides:
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Expert on-site guidance to ensure precise application and optimal repair results
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Training and consultation for in-house teams, helping them enhance welding efficiency and reliability
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Nationwide support and rapid service delivery to minimise downtime and keep mining operations running smoothly
With their deep understanding of mining industry demands and a proven track record, D&H Sécheron delivers not just products but results that save time, cut costs, and extend equipment life.
For companies in the mining industry looking to cut downtime and maintenance costs in mining? Piston repair using LoTherme 468 is a smart, strategic alternative to full replacements to deliver superior strength, crack resistance, and durability under extreme conditions. Backed by D&H Sécheron’s expertise and support, it’s a reliable way to restore performance and extend equipment life.
Ready to enhance your operational uptime with proven welding solutions, Connect with D&H Sécheron today!
For a detailed understanding of this case study, visit the full report here.
Key Takeaways
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Piston Repairs: Faster and more cost-effective than full replacements when using LoTherme 468.
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LoTherme 468: Specialised electrodes designed for strong, crack-resistant welds on cast iron pistons.
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Repair Efficiency: Reduces downtime and significantly extends equipment life in mining operations.
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Proven Performance: Trusted in real-world, high-stress environments with successful outcomes.
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Expert Support: D&H Sécheron provides technical training and guidance for reliable repairs.
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