Selecting a Wear Solution to Improve Equipment Reliability
For industrial companies that process abrasive materials, protecting equipment from wear is an ongoing challenge. Wear Solutions is a specialized branch of fabrication having to do with the selection and installation of material linings for specific applications. With numerous material options available for the variety of applications, the challenge lies in choosing a solution that considers reliability needs, process variability, and budget constraints to deliver long-term value.
GETTING STARTED ON A CUSTOM WEAR SOLUTION
Selecting a Wear Solution begins with a review of material handling and conveying operations and system configurations to identify opportunities for design improvements. Also, how various lining materials will react with specific media should be researched. Since there are often multiple solutions for a single application, options are evaluated on criteria such as installed cost, anticipated lifespan, and impact on process reliability.
TYPES OF COATINGS AND LININGS
Ceramics provide an abrasion-resistant lining, with the most common types being 90%-95% alumina, reaction bonded silicon carbide and sintered silicon carbide. Alumina linings are available in standard shapes and sizes and can come with a Zirconia additive for improved impact resistance. Reaction bonded silicon carbide is harder and more chemical resistant than alumina and can be made thinner to save on weight; however, it is more brittle than alumina. Sintered silicon carbide is used for orifices or wear linings in extreme environments where maximum erosion and or chemical resistance is required.
Ultra-High Molecular Weight (UHMW) linings are effective for low coefficient of friction and/or abrasion-resistant applications such as conveyors, tanks, cyclones, and chutes. These linings have a limited temperature range, typically less than 200°F.
Weld Overlays, such as chrome or tungsten carbides, are recommended for high temperatures, tough wear applications, or where there is an impact involved.
While these three are the most common solutions, other grades of materials are available for plates, pipes, and conveying equipment such as Abrasion Resistant (AR) plates.
QUALITY AND PERFORMANCE OF WEAR SOLUTIONS
Quality begins by selecting a wear solutions provider and installer with expertise in material handling and conveying operations. Since more than one material may work for a given application, seek an objective recommendation that meets your budget and performance needs.
During fabrication and installation, quality inspections should take place to confirm workmanship.
Once a Wear Solution is in place, monitor its performance to make sure it meets or exceeds reliability expectations. Changes in operations or in media properties signal that it may be time to reevaluate the Wear Solution.
SEFA has experience providing Custom Wear Solutions for industrial and manufacturing companies and utilities. Our team is equipped to evaluate operating conditions and provide customized solutions for one piece of equipment or entire systems. To learn more, please contact us.