Usura della saldatura

Welding wear technology refers to the production of composite wear-resistant parts by welding a hard alloy layer onto a steel substrate. These parts are designed to withstand abrasione, impatto, ed erosione in severe industrial environments while keeping high structural strength and low cost.

This technology is widely used in minerario, cemento, generazione di energia, impianti siderurgici, e sistemi di movimentazione di materiali sfusi.

Structure of Welded Composite Wear Parts

A welding wear component is a two-layer or multi-layer composite material:

The hardfacing layer is typically rich in carburo di cromo, boron, or tungsten carbide.

Welding Process for Composite Wear Parts

1. Base Material Preparation

The base steel is cleaned and prepared to ensure:

• Strong weld bonding

• No contamination

• Stable weld pool

Questo garantisce maximum metallurgical fusion tra gli strati.

2. Hardfacing Alloy Welding

Wear-resistant alloys are deposited onto the base steel using:

• Saldatura ad arco con filo animato (FCAW)

• Saldatura ad arco sommerso (SEGA)

• Saldatura ad arco aperto (OAW)

These automated processes allow uniform thickness, controlled chemistry, and high productivity.

3. Formation of Wear-Resistant Microstructure

Durante la saldatura:

• The alloy melts and solidifies

• Hard carbides form inside the overlay layer

• These carbides create an extremely hard wear surface

Typical hardness range: HRC 55–65

4. Controlled Cooling and Crack Pattern

Dopo la saldatura, controlled cooling creates:

• Fine, stress-relief cracks in the overlay

• These cracks prevent large structural cracking

• They improve impact and thermal stability

Questo è un designed micro-crack system, not a defect.

5. Cutting and Shaping

The welded plates are cut into wear parts using:

• Taglio al plasma

• Taglio laser

• Taglio a getto d'acqua

Then they are formed into:

• Liner

• Chute plates

• Bending segments

• Conveyor and crusher parts

Why Welding Wear Technology Is Superior

Compared with solid wear steel, welded wear parts provide:

• Much higher abrasion resistance

• Lower material cost

• Custom thickness and alloy design

• Easy repair by re-welding

• Maggiore durata

Applicazioni tipiche

Welded composite wear parts are used in:

• Mining chutes and hoppers

• Cement mill liners

• Sistemi di movimentazione del carbone

• Power plant ash pipes

• Steel mill conveyor systems

Questi ambienti coinvolgono elevata abrasione, sliding wear, e impatto.