Cement & Minerals • Ait Baha, MA
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Overview
On-site recharging of the segments of the clinker crusher rolls that undergo wear due to impact.
Industry
Cement & Minerals
Location
Ait Baha, MA
Component/Workpiece
HRP Crusher
Business Type
Integra - On Site
Job Type
Repair
OEM
FLS
Type of Wear
Tags
Base Metal
Fonte blanche
General Dimensions (mm)
Dimensions du segment : Diamètre est 465 mm, Largeur :350 mm
The challenge the customer was facing
Wear is observed on the teeth of the segments of the rollers due to the compression of the clinker blocks, whose temperature varies between 100 and 200 degrees Celsius. The customer usually replaces these segments, made of white cast iron, every two years.
Previous Service Life
2y
Competitor
FLS
How WA solved the challenge
Our solution is to use hardfacing with a first layer of Hardface AP-O flux-cored wire and apply 2 to 3 layers of Hardface TIC-O flux-cored wire.
Product Category
Consumables
WA Product Used
HARDFACE TIC-O
Diameter
2.4 mm
Job Duration
2w
Technical Advantages
The use of Hardface TIC-O flux-cored wire presents several significant advantages over the traditional method of replacing worn parts in industrial applications. 1. **Increased durability**: The Hardface TIC-O flux-cored wire is designed to provide superior wear and impact resistance. Its unique composition extends the lifespan of recharged parts, thereby reducing the frequency of replacements. 2. **Cost savings**: Recharging with Hardface TIC-O allows for the restoration of worn part surfaces, avoiding the high costs associated with purchasing new parts. This results in substantial savings over the long term. 3. **Performance improvement**: By using Hardface TIC-O flux-cored wire, recharged parts can achieve performance levels equivalent to, or even exceeding, those of new parts. This is particularly important in demanding work environments where reliability is essential. 4. **Application flexibility**: The Hardface TIC-O flux-cored wire is compatible with a variety of welding processes, allowing for easy application on different geometries and materials. This flexibility facilitates adaptation to the specific needs of each project. 5. **Reduction of downtime**: Recharging parts with Hardface TIC-O generally requires less time than complete replacement. This helps to minimize equipment downtime, thereby optimizing overall productivity. In conclusion, the adoption of Hardface TIC-O flux-cored wire and recharging techniques represents a beneficial solution for industries looking to optimize their operations while reducing costs and improving the durability of their equipment.
Service Life
2y
Photos and visuals for this case study
Solution Revenue
MAD140,000
2 layer(s) documented
Contributor
Amine Naciri
amine.naciri@welding-alloys.com
Created
April 3, 2026
Submitted
April 3, 2026
Approved By
Bastien Gerard
April 3, 2026