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Work Hardening & Impact Resistance in Crushing Equipment |
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Increase Wear Resistance For Lower Costs
Corewire provides expert support and specifically developed products to enable manufacturers and operators to extend plant service lives in a wide range of different environments and wear conditions. With a focus on reducing downtime and service costs products and techniques have been developed to enable on site repairs of even very large components. |
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Impact and Abrasion Resistance
Crushing applications tend to wear through impacts and high compressive loads more than any other mechanism. As such very hard materials (of the order of 65HRc and above) and work hardening materials become the product of choice. Corewire’s CC and MN range of alloys are ideally suited to these application. |
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The working environments experienced by crushers are varied but always extreme. A crusher will typically require a highly abrasive resistant surface, which must also be able to resist large impact stresses. In additionally, the crusher will need to absorb very high compressive loads. A typical repair schedule will include a high strength material to repair the body of the crusher. Then hardfacing layers using alloys to suit the particular application will be applied. These alloys are chosen for their primary mechanical properties:
- Ability to work harden
- Crack resistance
- Impact resistance
- Abrasion resistance.
A good example of the approach taken when repairing any of the wide range of crushing and quarrying plant is that taken with swing hammers. Commonly made from austenitic manganese steel, these components can experience dramatic levels and rates of wear. When repaired the hammers are built back to their original geometry using a weld metal that matches the base material composition. Then 1-2 layers of a Corewire chrome-carbide are deposited onto the areas of the hammer that see the highest wear rates, thereby protecting the hammer from one form of wear, whilst still exploiting the work hardening properties of the austenitic manganese steel underneath.
Repairs on site Reduce Downtime
The vast majority of Corewire’s welding consumables are available for welding by using an open arc process as well as a submerged arc method. The ability to use the wire in a shelf-shielded, open arc configuration means that in-situ repairs can be made, and with some crushers rolls being several meter across and weighing tens of tonnes this cost significantly reduce downtime and repair costs.
When an in-situ repair is undertaken it is difficult to remove fatigued material from the roll. By definition the surfacing materials used are going to be difficult to machine because of their hardness, and grinding by hand is a time consuming and difficult operation. To aid this type of repair Corewire developed Groovecore, a highly effective flux-cored wire for grooving. Groovecore is used with a powerful concentrated arc, and is capable of removing a layer up to 10mm depth in one pass, significantly reducing the processing time needed to prepare the surface.
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