Greetings from the frozen Eastern Wilderness.

You need not worry about any special needs for hardfacing your crusher rolls other than investigating the possible cost of having the manufacturer do it for you either on an exchange or shipping your rolls out during a shut down.

As long as you can match the hardfacing rod with the metal in your crusher rolls you should not have a problem-but if you cannot your welding supply dealer will give you the right rod or wire to do the job.

Just make sure that the groud is very secure by welding a ground clamp to the crusher roll itself to guarantee a good ground.

Dealing with the amperage for the welder is something your welder will have to decide when it comes time to do the hardfacing.

The other question is do you have the intent to do the work inside the crusher body itself? If so you must have adequate vewntilation for the welder as hardfacing is a very smoky job especially with dirt on the area being hardfaced.

This is a big safety consideration as I do not know the size of your crusher and if the rolls are stationary or set up with one stationary and one movable crusher roll. This may also limit the ability to adequately ground the crusher rolls since you risk frying the bearings due to stray current, remember that electricity is lazy just like water it finds the easiest way to get somewhere.

I spent way to much time inside a Gundlach roll crusher :^)

lzaharis ■

What Is Your Application?

Is There An Oppertunity In Your Application To Use A Ceramic Wear Bar (Blow Bar).

If So, Contact Me And I Could Contact My Ceramic Supplier And Try To Help You Resolve Your Troubles.

Nathan Phelan

NPhelan@stradaindustries.com ■

Some designs dont use autogenous zone teeth. In such designs, a special weldment can be applied that has a Brinnel of about 2100. THe non-tooth design helps control unacceptable breakage of product such as diamonds in soft matrix.

THe weld procedure is special. THe principle was developed in Germany. I am not sure if there is a North American weld shop that practices this method. I have the contact and brochure here if its of interest. Unfortunatley, they are not at my finger tips.

THe weldment is pricy but may fit the cost and replacement total life cycle cost formula. ■

I Am Not Familiar With ferro-silicon crushing, would you be able to provide a brief description of the material?? ■

Andre

What type of Tooth arrangement does your Roll Crusher have

we can supply Teeth hard faced by manufacturer

Simon Pearson

www.anglo-crushers.8m.net

Tel:+ 44 1484 543300

Fax:+ 44 1484 425217 ■

U could try the following people

Soudage - French

Vautid - German??

Both provide welding consumables for the rebuild of high chrome white cast metals eg table liners

U will need a buffer layer - to match yr parent matal (casting?) to build up and thern hardface layers to suit back to profile

Depending on the condtions - use stick electrode for open air welding or wire (sheilding gas) for good low wind environments.

Suggest having a set of rotable spares - re build set ready to go

U need to analysis costs - $ per kg laid and wear rates - existing and proposed. If really in to it, try several different at same time....direct comparision. Set it all up as a R&D claim/project and get some tax relief as well.

U could also try the casting route eg Magotteax - Belguim...well known for bi metallic castings - tough base and hard wearing work face. We use them extensively. M have also developed a combination casting with ceramic inserts (buttons) > get the toughness and high wear resistance in one.

Hope this helps mate

Cheers

James ■

you need not to replace wearing parts if you use our roller crusher. for more information, please visit our web

href="http://www.hkgfco.com" target="blank">http://www.hkgfco.com

our crusher has 7 features:

1. less energy cost due to high efficiency, comparing to other crushers , save more than 10% energy.

2. wear-resisting parts the wear-resisting parts can be used for more than 1 year.

3. the size of output stable it is very easy to adjust the output size, so the output size is very stable.

4. simple maintain our roller are designed very reasonably, can be used reliably. under normal conditions, it is not necessary to replace parts.

5. no pollution during work, almost no dust, noise level and vibration is very low.

6. less investment our roller crusher is of high quality with very good price.

7. our crusher can be used A: clinker first crush, B: super fine crush before grinder.

for more information, please visit our web:

href="http://www.hkgfco.com" target="blank">http://www.hkgfco.com

email:

href="mailto:hkgfcochina@yahoo.com">hkgfcochina@yahoo.com

contact: kim liu

wuhan ker machinery

Attachments

roller1 (JPG)

■

Originally Posted by dauna47

We own a roll crusher and we would like to reduce wearing problems on teeth crusher. We are looking at for welded hardfacing but we are so confused about which to use. Also, is there a special procedure before application (heat treatment, temperature...)?

Thank you, regards.

Andre Daunais

ADCI

Canada

We - Welding Alloys Group - have many year experience in this field. From Canada, you can contact Welding Alloys USA to get more details of application.

Mr. Dominic STEKLY (President)

dominic.stekly@welding-alloys.com ■

Please visit our website to view some possible solutions to your hardfacing or coating needs. Please state that you was refered by Brian Rogers to our sales team.

www.lasercladding.com ■

There are so many options when it comes to hardfacing that you might as well talk to The Man In The Iron Mask. He's a real hardfaced character.■

We are a supplier of hardfacing materials.

The main consideration for a welding procedure is your base metal.

Then you need to look at your application, you seem to have a heavy wear, so most traditional Fe based Chrome carbide will not perform best for you.

You may consider using some higher hand products and possibly composite alloys with tungsten carbide.

As for the welding process you have several choices :

On parts that big I would discourage using SMAW (stick electrodes) because the process is very slow and brings hot zones with high heat input in your base metal. Plus you loose a lot of material in the process (stubs)

GMAW is the most convenient and very easy to set in place in most shops, different wires and diameters will depend on the size of the part and the eventual rebuild to be done (with a bufferlayer/rebuild material)

Laser is a wonderful process, you can get very high life but for your type of equipment it might be a little costly and the repairability is poor. Most composite laser coating will not handle heavy impact very well.

PTAW is another good option, like laser it's not easy to set up in the field but you can adjust the coating to your specific problem and a lot of shops have equipment to lay down material on heavy equipment.

If you have more question feel free to contact us, we have offices and shops around the world :

www.durumusa.com

JM Tetevuide ■

Hi

Gather the speed would be low..do not know of lump size.

You can either use

Chromium Carbides or Tunsten Carbides in the welding consuambles

I do not know your parent tooth materials - you may be able to weld directly onto the worn teeth.

The aim would be to have a weld that can we re-welded several times....

I would go for Cr carbides and see how the performance goes from there.

Various suppliers should exist - need to look at

any preheat required and OK to do so

parent materials

fineness of the carbides

allowable heat input

depth of buildup required

hardness of the overlay deposit

practicality of surface overlay - ie insitu or in the shop.,...or have rotable rebuilds teeth?

time required for overhaul...any chance of automated rebuild procoess..maybe not..

Suggest contacing

Welding Alloys

Soudage - French

There are others eg Eutetic etc.

You have to make a start somewhere - could have a R&D project going on and get some $$ back - not all welding electrodes are the same.

As a general rule - you will need to get 4 x life over plain mild steel for Cr to pay off - excluding labour costs for removal/re assembly of main components if they have to be removed....the last item is where you get the payback and esp. if runtime is important.

Ensure that you have good record keeping to monitor performance - this can take some years if evaluating several products etc

Cheers

James ■