Case Study Library

Desgastes prematuros de cada punta estrella , atacaban la zona de impacto de la cabeza de la punta con materiales de alta dureza. En conjunto el usuario y WAAR se pusieron de acuerdo para buscar una soluciòn y que se minimizara el desgaste que acarreaba tambièn el cambio de las mismas , produciendo reparaciones con frecuencia y Parada de planta mensualmente. WAAR propone una soluciòn aplicando su sistema 3D-CARB-Ternium acepta probar y se compran 9 puntas estrellas las cuales se colocan en las posiciones mas delicadas 6-7 y 8. Con el tiempo se ve una mejora muy considerable

There is a discharge chute from a primary crusher to a conveyor belt. Currently, the liners in use are made of white cast iron and have an approximate service life of 90 days. The client is looking for a white cast iron solution with a service life of 6 months. To achieve this, the client proposes using bimetallic liners made of A36 steel and ASTM A532 Class II Type B cast iron. The client will provide the liner drawings.

Severe abrasion wear due to the silica contained in the bark of the wood chips transported by this fan

El sello del reactor presentaba desgaste y pérdida de geometría, comprometiendo la estanqueidad del equipo y la continuidad operativa. La reparación debía ejecutarse en sitio, con alta precisión y en un plazo reducido para minimizar la parada de planta.

There were cracks with some local wires and shorted the lifetime, and sometimes there was slag inclusion.

A customer sought a more effective welding solution for their client, who was using standard CO2 weld wire with tungsten powder. The requirement was for a product that achieves a hardness of 45-50 HRC to endure extreme abrasion, corrosion, and temperature challenges. The objective was to enhance performance and efficiency in welding operations. A specialized product designed to meet these specifications would offer improved durability and resistance to wear and corrosion, ultimately optimizing the welding process for demanding applications.

The case involves a breakdown requiring repair on a casting, with concerns about stock availability for necessary materials. In response, Mittal recommended the use of a 99% nickel welding wire to ensure optimal repair quality. This specific welding wire is crucial for achieving strong, durable bonds in the casting, addressing the technical challenges posed by the breakdown. By utilizing the recommended material, the team aims to enhance the longevity and performance of the repaired casting, effectively resolving the issues related to stock shortages and repair integrity.

The project involved a repair at a mining site where the customer faced limitations in using gas for welding applications. To address this issue, the customer sought a gasless hardface wire as a suitable alternative. Additionally, the availability of stock from competitors was a concern that needed to be managed. The solution provided focused on sourcing the appropriate gasless hardface wire, ensuring that the customer could proceed with necessary repairs without the constraints of gas usage, thereby enhancing operational efficiency at the mining site.

The customer experienced frequent breakdowns due to their supplier's inconsistent stock availability. Additionally, there was a demand for a superior welding wire that would enhance resistance to corrosion and erosion, providing significant advantages in performance. To address these issues, welding wire specifically designed to withstand environmental challenges. This approach would improve operational efficiency and meet customer requirements effectively.

A customer reported issues with welding wire, indicating that it became twisted and burned back on the contact tip, subsequently becoming lodged in the CO2 torch liners. This malfunction hindered welding operations. To address this problem, a thorough inspection of the welding wire and torch components is recommended to identify the root cause of the twisting and burning. Implementing regular maintenance and proper handling procedures for the welding equipment may also prevent recurrence of similar issues. Ensuring the quality of welding wire and compatibility with torch liners is essential for optimal performance.

Depending on the application, the knives are made of tool steel, which is heat treated after mechanical processing, or of mild steel and only the working elements (edges) are hardfacung with a suitable additional material. The customer expects a weld that would be abrasion resistant and, above all, good impact resistant.

The manufacturer suggested ceramic lining to fight abrasion. However, due to the 3-meter drop, ceramic tiles aren't performing well. The heavy limestone blocks cause them to crack or debond upon impact