Wear protection for cement production. In cement production, wear is not an issue. It is a decisive factor for plant availability and cost efficiency. Mills, roller presses and wear plates operate under extremely abrasive conditions. Raw material, clinker, coal or slag continuously attack the surfaces of critical components. For plant operators, every additional operating hour counts.
The challenge is not simply to achieve a hard surface. Wear protection must also be reliable and process-stable. Furthermore, it must be suitable for the specific component, base material, wear mechanism and maintenance strategy. In abrasive applications, the customer question is: how can critical wear parts reach the required operating hours with predictable performance?
Industry guidelines define expected operating times for wear-resistant components after overlay welding. These values help show why hardfacing quality is directly linked to maintenance planning and plant productivity.
Wear-resistant component category |
Expected operating time after overlay welding |
|---|---|
|
Slag vertical mill wear parts |
≥ 2,000 h |
|
Coal vertical mill wear parts |
≥ 8,000 h |
|
Raw material vertical mill wear parts |
≥ 8,000 h |
|
Cement clinker vertical mill wear parts |
≥ 2,500 h |
|
Roller press after online hardfacing remanufacturing |
≥ 4,000 h |
|
Roller press after offline cladding remanufacturing |
≥ 8,000 h |
Operating hour targets make the value of wear protection tangible. They translate technical performance into business impact: fewer unexpected stops, more predictable maintenance windows and better use of production assets. For cement plants, achieving reliable service life is therefore not only a technical requirement, but a key factor for operational efficiency.
As part of the UTP product portfolio, voestalpine Böhler Welding provides application-oriented wear protection solutions for exactly these critical areas. With UTP WEARcore C XD 62-P and UTP WEARcore C SC 63-O FW, high-performance flux-cored wire solutions are available for hardfacing applications exposed to severe abrasion. The welding consumables enable hard, wear-resistant overlays and support the service life requirements of highly stressed components.
Especially in vertical mills and roller presses, an application-specific UTP solution is essential. Different welding strategies apply, depending on the base material, component geometry and required deposit thickness. For severe abrasion with low impact stress, UTP WEARcore C XD 62-P offers a suitable solution. In scenarios with very high abrasive loads, UTP WEARcore C SC 63-O FW provides a robust choice. Here, the CrNb alloyed weld metal offers clear advantages.
Criterion |
UTP WEARcore C XD 62-P |
UTP WEARcore C SC 63-O FW |
|---|---|---|
|
Typical application |
Hardfacing for severe abrasion and low impact stress |
Hardfacing for very high abrasive loads, e.g. wear plates, crusher and conveying components |
|
Material concept |
High chromium carbide weld metal with strong abrasion resistance |
CrNb alloyed weld metal with primary and eutectic carbides as well as Nb carbides |
|
Hardness |
Typically up to approx. 63 HRC in the pure weld metal |
Typically approx. 63 HRC as welded |
|
Deposit build-up |
Multi-layer hardfacing possible; exact design depends on component and wear pattern |
Typically 10 to 12 mm in 2 to 3 layers |
|
Customer benefit |
High wear resistance, robust overlay, well suited for continuously abrasive processes |
Highly resistant solution for abrasive applications up to max. 450 °C |
Assess abrasion, impact stress, temperature and component geometry
Define the suitable UTP WEARcore flux-cored wire and deposit build-up
Match parameters, layer build-up and bead appearance to the application
Improve wear protection and make maintenance intervals more predictable
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Our UTP experts support you in selecting the right WEARcore solution for your application.
