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Caso di éxito
UTP Welding Consumables for the Cement Industry
voestalpine Böhler Welding is committed to working closely with customers to develop optimal surface protection solutions for critical components in the cement industry. Read more in our new success story.
A strong partnership: GTV Engineering and UTP
GTV Engineering Limited, based in central India, has been a leader in heavy engineering for 45 years, manufacturing essential fabricated and machined components for the cement, minerals and steel sectors.
GTV’s collaboration with UTP began in 2015 when the company sought a technology partner for manufacturing abrasion-resistant wear plates. Today, GTV supplies these wear plates not only in India but also to Japan, Indonesia, Sri Lanka, Nepal, the UAE, Egypt, and Germany.
Given the extreme wear conditions in cement plants, the quality of wear plates must be world-class to ensure machinery durability and optimal performance.
Challenges in cement production
Cement production involves grinding raw materials into fine powder using vertical or horizontal mills. These operations generate high levels of abrasion, intensified by 24/7 plant operation. The resulting wear on machinery leads to efficiency losses, reduced equipment lifespan, and increased maintenance costs.
To combat these challenges, critical machinery surfaces must be protected with high-performance wearresistant solutions. One of GTV’s key solutions is overlay welding on wear plates, whiwch significantly enhances component durability.
Wear plates: A high-performance solution
GTV manufactures wear plates in various grades and specifications, designed to withstand impact, abrasion, erosion, and heat. These plates are further optimized with welded overlays using chromium or tungsten carbide-based consumables, ensuring superior abrasion resistance.
| Wear plate thickness options | |||
|---|---|---|---|
| 5 + 3 mm | 6 + 4 mm | 8 + 5 mm | 10 + 6 mm |
Solution advanced welding consumable: WEARcore XD 62-O
Classifications:
- EN 14700: T Fe 16 / DIN 8555: MF 10-GF-65-GT
WEARcore XD 62-O is an open-arc metal-cored designed to resist grinding abrasion with low impact. This wire has typical microstructure of Primary Carbides and M7C3 eutectic carbides in an austenitic matrix. The deposited layers naturally develop stress relief cracks, enhancing wear resistance.
Technical details:
Weld Overlay Results
| Welding characteristics | Results |
|---|---|
| Welding position | PA / 1G |
| Current | 300 - 500 Amps |
| Arc Stability & Force | Excellent |
| Welding performance | Low spatter and minimal fume |
| Bead shape | Uniform, flat bead |
Hardness
| Layer | Specifications Hardness (HRc) |
|---|---|
| Multilayer | 61 - 64 |
| Two Layer | 57 - 58 |
| Single Layer | 48 - 49 |
Tests confirm that WEARcore XD 62-O delivers excellent weldability and hardness from the first layer. Weld beads remain free from slag and spatter, ensuring reliable overlay protection.
GTV Engineering: Delivering proven results
With these high-quality abrasion-resistant wear plates, GTV Engineering provides optimal solutions for critical components such as classifiers, ducts, grit cones, louvers, hoppers, chutes, and separators. The company serves leading European OEMs and major cement producers in India, including Ultratech Cement, Adani Cement, Shree Cement, Wonder Cement, and Dalmia Cement.
Strategic decision to in-house wear plate production
To ensure consistent quality and timely supply, GTV established its own wear plate production, collaborating closely with UTP for technology support.
Our partnership with UTP was one of the best decisions for GTV. With their welding consumables and expert support from Germany, we successfully optimized our welding process. Since then, we have had no quality issues, and our wear plates perform exceptionally well in the most abrasive environments.
Through this successful collaboration, GTV and UTP continue to provide superior wear protection solutions, ensuring durability and efficiency in the cement industry’s most demanding applications.
You want to know more about our solutions for the cement industry?
With our enhanced portfolio of welding consumables and metallurgical know-how we are your preffered partner for welding solution in the cement industry.
You have questions or want to learn more? Feel free to contact us or check out our industry pages and whitepaper for more detailed information.