Case Study Library

Original Gas Ring was fabricated out of AR400. This is not a good material to use in a high abrasion / small particle application.

The quality of Hardfacing from Pronamic. Delamination and Breakouts of hardfacing in the Hi-Pressure/Grinding Zone & Heel of Rolls.

Efficiency problems, rolling balance, issues with stopping at any moment, vibration, rolling wear; the customer does the repair work but now they request an experts to do the implementation.

Premature failure of the Rolls like deep fire cracks and roll wear out .This resulted in break-outs and reduced Heat size leading to expensive down time of the Caster operation adding to the increased TCO Customer was earlier using Rolls as per OEM drawing and cladding was done by other vendor. But did not get the desired life from these top zone rolls(from Mould to Bender zone) Dia of the rolls range from 130 mm to 165mm .

Problem Description – Plug Feeder Screw Hardfacing Failure Hardfacing Configuration The plug feeder screw is made of stainless steel, with the screw flight protected by three layers of chrome-based 431-G buffer material, followed by two layers of tungsten carbide on the flight outer diameter (OD). The front flight corner is also reinforced with a 431-G layer and tungsten carbide coating to improve wear resistance. Design Gap at Ribbon Back Face However, the ribbon back face is directly coated with tungsten carbide without a 431-G buffer layer. This creates poor bonding and low toughness at the interface, especially at sharp edges. Failure Mechanism Under high pressure, abrasion, and cyclic loading, stress concentrates at the sharp back face edge. Without a ductile buffer layer, the brittle tungsten carbide coating tends to crack and peel off. Operational Impact The detached carbide particles enter the refiner system and damage the refiner segments, leading to increased wear, reduced efficiency, and higher maintenance costs.

According to our customer experience, the AR400 provided a service life of about 2 years, whereas after switching to Hardplate 6+6, the lifetime has extended to approximately 4–5 years.

The four-roll lower roll in current operation experiences rapid wear, resulting in a short service life of approximately 6 months. This limited durability leads to frequent refurbishments, increased maintenance costs, and production downtime. The accelerated wear reduces overall efficiency and reliability of the system, creating a need for a more robust solution that can extend the roll’s operational lifespan and minimize interruptions.

Required Gear Pinion Teeth Build-Up Jobs** The objective of this project is to execute gear pinion teeth build-up jobs that ensure cost-effectiveness while providing high-quality service and extended operational lifespan.

Tube degradation occurs due to corrosion and erosion caused by steam blowing from soot blowers and the flow of bed material. Although the tubes are coated with Ni-Cr-based thermal spray, cracking and delamination of the coating occur.

Specifications for the screw conveyor in steel dust handling equipment ・Base material ・Operating temperature 800°C to 1000°C ・Function of the screw Primarily designed to convey pellets approximately 100 mm square, it also serves to scrape out pellets that have become stuck to the furnace floor. Shaft: SUS316L (water circulates inside the shaft) Blades: Heat-resistant steel (equivalent to SCH46) Previously, repairs were carried out by another company, involving restoration to the specified height using SCH46 alloy steel, followed by a single layer of hardfacing with a material equivalent to Stellite No. 6. Due to rapid wear, repairs had to be repeated every six months.

Traditionally, manufacturers have used expensive slit rollers that cannot be remanufactured; as delamination occurred during operation, leading to a reduction in shredding efficiency, customers have raised doubts about the cost-effectiveness of this type of roller.

the tires and wheels of the oven (reactor) initially have a concave and convex shape, the plan with this work is to leave them as parallel as possible to the horizontal