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Rebuilding & Hardfacing of Wear Parts
Rebuilding and Hardfacing of wear parts is well known and proven maintenance practice.
Metal parts under high mechanical stress suffer due to wear, which causes them to lose dimension and functionality. Hardfacing, also known as hard surfacing, is the application of buildup or wear-resistant weld metals to a part's surface by means of welding or joining. Most worn parts don't fail from a single mode of wear, such as impact, but from a combination of modes, such as abrasion and impact. For example, vertical mill grinding rollers are usually subjected to abrasion and impact, and depending on composition of feed, one mode may be more dominant than another.
For example, the roller tyres and tables of vertical grinding mills are affected by mechanical stresses causing components wear and result in misalignment and more consumption of energy. Every Vertical Mill operator wishes to have energy efficient, high run-time factor and no unexpected fails and stoppages. Therefore the managers prefer rebuilding of wear parts than costly procurements. Our rebuilding service is dedicated to help managers to achieve highest possible run-time with the lowest cost.
Vertical Mill Tires, Tables, Rollers, Holders, Seals, Clamps & Bolts
Types of Welding
“Rollers Tyres and Tables of Vertical Grinding Mills can be rebuilt upto 100mm by hardfacing”
In addition to rollers and tables of Vertical mills, all metal parts which face high wear due to abrasion and impact in cement industry can be hardfaced and their life can be increased. It is important to note that “Abrasion” and “Impact” collectively accounts 65-70% of wear however one mode may be more dominant than other and this also dictate the welding product to be used.
Years ago rebuilding was just a hardfacing job. We have changed it pioneering rebuilding wear parts using top quality wire to achieve original dimensions and life time better than original. Flux cored Hardfacing wire is High-alloyed tubular C-Cr-Nb-B based wire for extremely wear-resistant deposits on parts subject to heavy abrasive wear by minerals.
We have spent enough years and achieved experience to rebuild different wear parts and perform complex hardfacing jobs. Our rebuilt parts have exceeded life time of original parts many times.
We have carefully studied wear profile of worn parts and tested almost all popular welding consumables and products available around the World. We have now attained enough experience to offer most suitable and cost-effective reliable solution which help managers to achieve highest possible run-time with the lowest cost.
Rebuilding and Hardfacing Services
Welding Wire vs. Welding Electrode
Welding Wire (MIG process) is good in every aspect as compared to Welding Electrode (Stick process).
We can rebuild wear segments of Rollers & tables which are worn up to 100mm. We have completed rebuilding tasks for different Vertical Mills. Today Ecorporates rebuilding service is the most reliable and cost saving technique for vertical grinding mills. We help clients to avoid unexpected failures, high costs of replacements and production losses.
We offer Rebuilding and Hardfacing of wear parts especially Vertical Grinding mill Tyres and Tables to cement plants all over World. If the end-user has spare set of rollers/tables then it is preferred to perform rebuilding task in temporary workshop at client’s site. However, we also possess great expertise and experience to perform rebuilding on the Grinding Mill. We take great care and employ industry standard precautions to avoid damage to mill Bearings by using Magnetic Cam Clutch during rebuilding job.
We are among few suppliers of wear resistant material in composite metal ceramic. Composite metal ceramic has high toughness and better high wear resistance feature.
Metal matrix composite is composed with alloy and ceramic through special casting, heat treatment process which gives 2-3 times better life than traditional high chromium alloys. The ceramic particles are placed on the surface of high chrome material layer to form the ceramic metal composite material layer. Composite metal ceramic has both features of high wear resistance of ceramics as well as good mechanical properties of metal materials, therefore it does not easy wear.
This strengthen structure increases the surface friction and effective grinding area and help to improve the grinding efficiency and reduces the power consumption.
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