Case Study Library

When the cooling screw wears, the processing capacity decreases, so regular replacement and repair are carried out; however, this creates issues such as securing sufficient maintenance time and the high associated costs.

The customer doesn't have spare parts to replace, so stopping the mill would result in significant losses. However, we have never used a hardfacing ceramic table liner before.

Due to faster wear on the Drive Rolls the gap between Slab and Roll increases thereby the weight of Slab on the adjacent rolls is not uniform, causing induced wear on the adjacent rolls and also affecting the Caster speed. This is also one of the reason for Break outs in Caster.

Sugar Mills operate under extreme conditions on a 24 h / 7 days during the season (6 months), which results in wear across of all area of the roll mill and this component is the key to extract and produce sugar; this process is the second operation after shredding the cane.

Q3 2025, WA USA sold High Tech Reman an R3000 weld lathe under a wire supply agreement. This involved them swapping from Lincoln 96-S to our Chromecore 420-S as a close chemistry cross. Going into the application, we knew they were having small cracking issues, likely attributed to hydrogen cracking due to their chrome plating and stripping process. We also thought it could have been process issues with an old, home-build, weld lathe. After selling our machine and supplying 420-S, the continued having issues, even after process optimization. We then switched them over to Chromecore 420L-S at the beginning of 2026 to lower the carbon level from .3% to .2%. Their re-works went from 25% to complete elimination by this simple wire change.

Bucyrus 495 shovel, this component works 24 hr / 7 days in a highly abrasive environments, erosion, impact and corrosion conditions

Back-up-roll and Work-roll chock bearing sleeve refurbishment for Hot and Cold Rolling plate mills. Tapered inside diameter of chock bearing sleeve fits over roll journal. Outside diameter of bearing sleeve rides against soft babbitt bearing fitted to the inside diameter of the chock bearing housing. By design the babbitt bearing will wear and needed to be serviced / and or replaced. For the most part the sleeves don't see much wear, but overtime some wear does occur and through servicing some of the sleeve material is ground and polished back true. Eventually the outside diameter dimension become too small and needs to be restored. Traditionally, because of the small amount of wear / material loss the outside diameter of the chock bearing sleeves would get restored via a metalizing thermal spray process, which was limited to 1.5mm in thickness via a mechanical type bond to the sleeve. Plate rolling mills are notoriously hard on rolling mill equipment, and their heavy loading of the rolling mills exceeds the mechanical strength limit of the thermal spray coating. In order to achieve thicker refurbishment depth and increased bond strength of the refurbishment coating, a weld overlay solution was developed by Cunova with the support of Welding Alloys. The weld refurbishment process incorporates the use of a modified WA R3000 welding lathe (Mod to accept and control diameters up to 1.25m), WA's BUF-S 1.2mm (for edges of sleeves), WA's BUF-S 2.4mm (for main body of sleeves), and WAF 325 flux.

The media being pneumatically transported is made up of mixed waste with inclusions of crushed glass and plastics, this causes severe abrasion on the elbows. As there is no crane access, the parts must be changed by hand when they wear so need to remain lightweight.

Operational lifetime of the ø250 driven caster rollers. Customer wishes to find a cladding material that gives a longer rollife in operation.

The biggest Challenge is to have averuthing (wire, machines, People) available and ready to be on site as Quickly as possible

This on-site approach saved the client from the downtime of dismantling and assembling the equipment, successfully completing both roller in just 15 days.

Une usure est observée sur les dents des segments des rouleaux en raison de la compression des blocs de clinker, dont la température varie entre 100 et 200 degrés Celsius. Le client procède habituellement à un remplacement de ces segments, fabriqués en fonte blanche, tous les deux ans.