Build wear resistance on a load-bearing, weldable substrate through build-up, buffer and wear layers. Applications include HPGR roll surfaces, vertical mill rollers and tables, crusher rolls and teeth, screws and chute overlay plate. Repairability depends first on the substrate, cracks, distortion and remaining dimensions.
Hardfacing alloys provide surfaces for abrasion, impact wear, metal-to-metal wear or hot wear. Repairs must also restore geometry, concentricity, dynamic balance and mounting faces. Selection must account for substrate weldability, dilution and permitted cracking to prevent premature delamination.
Studs are cemented carbide parts and require a separate specification from roll hardfacing alloys.
Check substrate type, existing overlay chemistry, weldability, wear profile and whether in-situ or workshop repair is permitted.
Keep hardfacing away from bolt holes, mating faces, critical tooth-root sections and precision-machined areas.
| Part | Main Failure Modes | Candidate Processes | Required Checks |
|---|---|---|---|
| HPGR Roll Surfaces / Sleeves | Flattened wear profiles, edge erosion, hardfacing grid spalling and localized cracks. | Reprofile and apply buffer/wear layers; replace studs and restore substrate areas according to the studded roll design. | OEM design, substrate, roll diameter, concentricity, cracks, roll pressure and wear scans. |
| Vertical Mill Rollers / Sleeves | Profile loss, grooves, localized spalling and uneven wear. | Remove damaged overlay, treat cracks, apply build-up/buffer and hardfacing layers, then grind to profile. | Substrate, previous consumables, permitted heat input, profile templates, mass and balance. |
| Vertical Mill Tables / Segmented Liners | Grinding-track wear, edge erosion, segment joint damage and fastening-area damage. | Workshop or in-situ hardfacing, segment replacement, reprofiling and joint repair. | Table diameter, segmentation, substrate, minimum remaining thickness, thermal distortion and mating roller profile. |
| Crusher Rolls / Teeth | Blunt tooth tips, tooth-face spalling and root cracks. | Where repairable, use a tough build-up layer and wear layer. Replace the base part if cracking or distortion is severe. | Substrate grade, tooth profile, impact, speed, crack location and remaining section. |
| Chute Overlay Plate / Wear-resistant Pipes | Wear-through, joint erosion, backing plate distortion or delamination. | Steel backing with carbide hardfacing; provide buffering or segmented construction according to the impact zone. | Flow direction, drop height, particles, temperature, bending requirements, fastening and joints. |
Distinguish permitted stress-relief cracks in hardfacing from unacceptable delamination and substrate fatigue cracks. Acceptance requires more than visual appearance or a single hardness reading.
After cleaning, record substrate material, existing overlay, wear map, remaining dimensions, cracks and distortion to determine repair or rejection limits.
Specify preheat, interpass temperature, consumables, dilution, bead direction, heat input and controlled cooling. Use matching-material test coupons where required.
Record welding parameters, consumable batches, temperatures and dimensions by layer. Control welding sequence, distortion, hardfacing crack direction and interfaces.
Check profile, dimensions, concentricity, mass/balance, hardness distribution and NDT. Conduct post-repair trial operation of rotating parts according to equipment risks.
Parts Requiring Engineering Assessment Before Repair: Main shafts with deep fatigue cracks, gear roots, bearing seats, critical highly stressed welds, and safety-critical parts without material or service traceability require failure and engineering assessment. Replace them where necessary.
Material References: voestalpine Böhler Welding Mining Hardfacing; Metso HPGR Roll Surface and Stud Design. Specify consumable grades and layer design for the substrate and operating conditions.
Provide the equipment model, part drawings, substrate material, previous consumables, remaining dimensions, crack/NDT records, wear photographs, operating loads, quantity and target repair dimensions.
ANRANST provides customers worldwide with coordinated consulting, supplier sourcing, quality control and finished-part delivery for custom parts, wear parts and industrial spares from China, with scope to support other custom industrial parts.
Equipment and part identification, drawing review, material selection and manufacturing feasibility assessment.
Match requirements with suitable manufacturers in China and coordinate the exchange of technical information.
Drawing confirmation, material and process control, production tracking, inspection and acceptance coordination.
Coordinate manufacturing, quality confirmation, packaging and delivery of complete finished parts.
Provide the existing model, drawings, drawing or part numbers, materials or operating conditions so we can identify the appropriate technical review and supply route.
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