Case Study Library

Previously, new hammers were hardfaced using Diffusion's Cordiff 600 TIC. However, several issues were identified, including scattered spatter, poor weldability, and an uneven hardness distribution across the hardfaced surface.

The customer utilized conventional semi-automatic, locally manufactured equipment for hardfacing and profiling applications. However, they encountered several challenges, including irregular weld beads, uneven ripples, and porosities in the weld deposits. The preheat temperature of 250°C and interpass temperature of 280-300°C were adversely affecting the efficiency of their equipment, leading to prolonged execution times and frequent process breakdowns.

Due to a significant increase in the price of new rollers and delays in delivery, they were facing the issue of being forced to suspend operations for an extended period.

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430-S, 2nd layer 414-S, and 3rd layer 414-S But interbeed corrosion results in spaling and diameter loss.

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430-S, 2nd layer 414-S, and 3rd layer 414-S But interbeed corrosion results in spaling and diameter loss.

In this case, for a boiler newly constructed in 2001, the waterwall tubes had become significantly thinned due to corrosion, leading to the planning of a panel replacement project. These panels had not been overlaid with Alloy 625.

The wear and tear is caused by friction and abrasion from animal feed, such as hard corn, leading to punctures. The expected service life is approximately 4-6 months. Customers use insulation materials or scraps of fabric to patch leaks and then use silicone sealant. These repairs are time-consuming due to the frequent presence of multiple leaks, and involve the expense of disposing of the spilled animal feed.

Due to the coarsening of sinter, we reduced the secondary crusher’s roll gap by approximately 50mm to improve crushing performance. However, this adjustment has led to accelerated wear on the teeth tips. Consequently, we have been requested to enhance the robustness and durability of the teeth.

The ceramic rolls of the customer were completely worn out, which is why they had to stop the mill. The new rollers had already been ordered, but the delivery time take another six months to arrive, so they were looking for a solution to continue the production during those six months.

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430-S, 2nd layer 414-S, and 3rd layer 414-S But interbeed corrosion results in spaling and diameter loss.

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430S, 2nd layer 414S, and 3rd layer 414S But interbeed corrosion results in spaling and diameter loss.

The roll life is today with OEM spec. cladding approximately 6 month. Customer aims to reach 50% increased lifetime; 9 months operation. Cladding today is; 1st layer 430-S, 2nd layer 414-S, and 3rd layer 414-S But interbeed corrosion results in spaling and diameter loss.