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Welding Consumables for Lower Maintenance Costs |
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Pro Active Maintenance Reduces Costs
The operation of large plant is going to result in wear. Wear of the conspicuous, product handling components such as buckets, rails and rollers, and wear of less obvious parts such as roller journals and bearing housings, or caterpillar tracks, idlers and track wheels. And it has been shown that problems with the rollers and associated parts can contribute approximately 30% of total machine maintenance costs. The secret to operating this plant as efficiently as possible is to be pro-active with maintenance (prevention be better than cure), and to extend the interval between maintenance periods as much as possible.
Welding Consumables for Hardfacing & Wear Resistance
Corewire has the materials and equipment to enable you to do this. Take as an example our experience in the steel sector. The production of semi-finish steel products such as slab, plate, strip and sections can lead to pronounced attrition of the product handling rollers. Our Weldclad brand of materials have become widely known, used and trusted around the world for performance and ease of use; with our Weldclad 3 material becoming the benchmark for quality in cladding continuous caster rollers.
The use of Weldclad materials can help control your maintenance costs in a number of ways. Most obviously, the increased service life you will achieve from your rollers will mean rollers being repaired less often, and thereby reducing the downtime on your plant.
Servicing With Weldclad Consumables Increases Service Lives
Eventually, the rollers will need repair. However, the unique composition of Weldclad materials means that the wear is often just superficial, and in many cases the only action required is to dress the roll's surface and return it to service. Just one such case involves a major steel plant in Northern China. To date the rolls have dressed and returned to service no less than three times, achieving a total tonnage through put approaching 5 million tonnes. |
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- Rolls last longer therefore don’t need to be repaired as often.
- Longer lives = fewer shut downs to remove segments therefore improved productivity
- Fewer welding machines are required to do the same job, ie deposition rate of 10-12kg/hr vs 7-8 kg/hr. Therefore lower initial costs.
- Flatter bead profile means less weld metal needs to be removed at the final machining stage; therefore less wasted material, less lathe time & associated costs.
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