Crushing and sizing components used for mining applications are subject to severe wear from impact, high-stress abrasion and gouging. Breakdown of system sizing screens, crushing hammers and cone crushers cause significant mining production disruption. Innovative Metco Joining & Cladding weld and cladding hardfacing materials are designed to protect crushing and sizing components resulting in extended component life, increased production uptime and lower overall costs for the mining industry.
The existing alternative — manganese steel weld alloys — is too soft and has low abrasion resistance; therefore, it is not the best choice for these tough applications.
The use of high-performance materials and overlays for crushing and sizing components usually requires special processes and equipment. For manufacturers of mining equipment and spare parts, as well as hardface welding companies, this means that they are either difficult to use, and/or economically not viable.
Metco Joining & Cladding is a global manufacturer and supplier of tungsten carbide, tungsten titanium carbide, carbide blends and innovative iron-based materials designed to provide significant component performance improvements. However, we go far beyond that with our capability to develop unique materials that perform better and last longer.
SEM photomicrograph of PlasmaDur 51027 showing a typical blended carbide powder.
Our novel approach is to computationally design and develop materials that can be applied using conventional GMAW (MIG) welding equipment. Nevertheless, the new Metco manganese steel weld overlays provide hardness as high as HRC 45 to 55 (welded) and HRC 60 (work-hardened). Thus, these new materials outperform conventional manganese steel weld overlays.
Metco 1040A, Metco 8250 and Metco 8233 have been applied onto primary and secondary crusher hammers. These large rotating hammers are subject to constant attack by impact and abrasion in a cement limestone mine in Asia. The fine microstructure of the materials reduced the propagation of cracks and resulted in superior impact performance. It increased crushing efficiency and reduced production downtime by more than 100% compared to conventional manganese steel hammers. This reduced the customer’s maintenance cost tremendously.
Metco Joining & Cladding pioneered the development of new iron-based materials designed to equal the abrasion resistance of tungsten carbide overlays, but with significantly higher impact resistance. Metco 8224 has been applied on shaker screens in an oil sands processing facility in Canada, in comparison to existing tungsten carbide PTA (Plasma Transfered Arc) applications. The lifetime of the shaker screens hardfaced with Metco 8224 increased 3-fold, with a 50% reduction in material cost and no under-bead cracking.
Metco 8224 has also been used on cone crushers as a replacement of tungsten carbide weld overlays for its higher impact resistance at lower cost. It was applied using a conventional MIG welder. During the welding process, Metco 8224 produces fine scale vanadium carbides and molybdenum borides that provide high abrasion resistance throughout the entire weld. This high performance is achieved in the first layer of the weld overlay. Metco 8224 has become a popular choice among OEM manufacturers due to its superior performance and lower application costs. Metco 1030A is the PTA and laser cladding equivalent to Metco 8224.
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Key Fe based GMAW Materials:
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