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Crushing and sizing components must be hardfaced with high performance materials and overlays to do their job reliably and with long service life. But the access to these materials can be challenging. Oerlikon Metco’s innovative weld hardfacing alloys for crushing components are breaking new ground in the mining industry.

Computationally Designed for Highest Wear Resistance

The use of high perfomance materials and overlays for crushing and sizing components requires special processes and equipment. For manufacturers of mining equipment and spare parts, as well as  hardfacing welding companies, this means that they are either difficult to use, and/or economically not viable. The existing alternative — manganese steel weld alloys — is too soft and has low abrasion resistance; therefore, it is not suitable for this tough application.

The Alternative to Manganese Steel that is as Robust as You Need It

Oerlikon Metco’s novel approach is to computationally design and develop materials that can be applied using conventional GMAW (MIG) welding equipment. Nevertheless, the new Oerlikon Metco manganese steel weld overlays provide hardness as high as HRC 45 to 55 (welded) and HRC 60 (work-harden). Thus, these new materials outperform conventional manganese steel weld overlays.

Customer Examples:

Metco 8224 has been applied on shaker screens in an oil sands processing facility in Canada, in comparison to existing tungsten carbide PTA* 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. *PTA = Plasma Transferred Arc

Metco 1040A has 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 Metco 1040A 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.

Key GMAW Materials:

  • Metco 8250
  • Metco 8233
  • Metco 8226
  • Metco 8224
  • Metco 8248

Key PTA Laser Materials

  • Metco 1040A
  • Metco 1030A
  • Metco 1051A
  • Metco 51322
  • Metco 51027

Example:

Metco 8250 provides 5 times better wear resistance than a competitor product and 3 times better than manganese steel.

Benefits of Oerlikon Metco’s new material solutions for crushing and sizing components:
  • High wear resistance and high impact resistance result in an increased service life of crushing and sizing components of 30% to 400%
  • Lower changeout and labor cost due to less frequent change out of components
  • Reduced machine downtime
  • Hardfacing maintains the design geometry of crushing equipment. This maintains equipment efficiency and improves throughput.
  • Increased crushing and sizing efficiency lowers the cost per ton of ore extracted,
  • Increased efficiencies, lower changeout costs and reduced logistical burden result in lower costs per hour of operation.
  • Easier application, as only one single material is needed, and no further equipment than standard GMAW welding equipment

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