Creative Ideas for Real Life Wear Protective Solutions DURUM GmbH has developed produced and distributed wear protective products for more than 25 years. This knowledge and experience has enabled us to introduce new wear protective coatingss to increase the lifetime of machinery and to reduce the costs for maintenance of wear and erosion of exposed surfaces and components. In addition to delivering high quality wear protective materials to our customers, our competent team consults in every specific application to provide tailor made solutions. We have the knowledge to provide engineering support for the design of new parts. These components are tailor made and fabricated for machine parts, tubes, segments, mixer barrels, bars and more. Used components can also be regenerated according to customer requirements. We offer: • • • • •

Wear plates (Open Arc and PTA) Wear protective parts according to design requirements Regeneration of worn parts Coating of new parts, also full-production run Consulting, development, conceptual design and wear analysis services

DURUM works with leading research institutes and universities in the development of new materials and technology for wear protection solutions. We analyze the customer’s wear problems and provide the essential solution. Combined research, development and integrated production is our guiding theme. We work with the following universities: Technical University of Clausthal, University of Hannover, University of Ilmenau and Technical University of Chemnitz.

Our welding workshop is certified according to the DIN EN ISO 3834-3:

CP - wear plate The fabrication of the CP – plate is carried out by use of a core wire welding process. The extreme wear resistance is achieved by use of high quality CORODUR core wire consumables with high Chromium and Carbon content. The addition of complex carbides enables the formation of a high content of Chromium- and special carbides, so that the required properties are achievable in the first layer in accordance to the DIN 855 E10-60G. The characteristic, hypereutectic weld metal of the FeCrC-hardfacing alloy consists of large, primary deposited carbides of the type M7C3, embedded in the eutectic matrix. The content of the primary carbides mainly affect the wear resistance and can be determined according to Maratray as follows: % K = 12.33 (% C) + 0.55 (% Cr) – 15.2 % The increasing carbide content is related to steady rises of the Cr- and C content. Through application of core wires CORODUR 56 and 62, the primary carbide content can be increased significantly. The addition of complex carbides e.g. NbC subsequently increases the wear resistance performance of the plates. Typical / standard dimensions: Base material

Coating

Total

weight

(mm)

(mm)

(mm)

(kg/m²)

5

3

8

62

6

4

10

78

6

5

11

85

8

5

13

100

8

8

16

125

8

18

140

10 Further dimensions on request.

Delivery forms: DURMAT- CP – plates can be delivered as pre-finished blanks with fixation elements, sinkhole bores or others. Recoating is carried out with similar alloy electrodes or core wires. See above the core wire catalog.

st

CP - PLATE CP 960–microstructure, 1 layer

st CP - PLATE CP 1000–microstructure, 1 layer

DURMAT®

CP 960 FeCrC-wear plate

General characteristics: ®

DURMAT –CP 960 is a composite hardfacing plate consisting of a weldable steel plate and a wear resistant coating composed of the core wire DURMAT FD 55. The hardfaced coating of C-Cr-alloy is related to the alloy group Fe14 according to EN 14700 (group 10 former DIN 8555). Chromium carbides in combination with borides and other metals produce an adamantine and wear resistant coating. Applications: These coatings are useful in the ceramics industry, mineral crushing, mining industry, fan and other applications that have high demands for wear resistance. Technical data: Plate dimensions: Coated area: Base material:

2,850 x 1,300 mm *) 3.70 m² S235, S355, S690QL (others on request)

Chemical composition 1st layer (wt-%): Fe

Cr

C

Mn

Carbide content

Balance

28.8

4.85

0,6

60

Hardness of the weld material: Maximum working temperature:

approx. 60 HRC approx. 350 ° C

® Advantages of DURMAT –CP960

-

Complete analysis even in the 1st layer High protection for many wear mechanisms High deformability, the plates can be cut via plasma Easy weldable based material

*) Further plate dimensions on request

DURMAT®

CP 1000 FeCrNbC-wear plates

General characteristics: ®

DURMAT –CP 1000 is a composite hardfacing plate consisting of a weldable steel plate and a wear resistant coating composed of a core wire coating DURMAT FD 60. The hardface coating of C-Cralloy with additional incorporated complex carbides related to the alloy group Fe15 according to EN 14700 (group 10 former DIN 8555). Chromium- and Niobium-carbides in combination with borides produce an adamantine and wear resistant coating applied for components exposed to energizing wear. This is not suitable for impact and impinging loads. Applications: This is useful for cement and concrete pumps, coatings for the ceramics industry, mineral rushing, mining industry, fan and recycling industries. Technical data: Plate dimensions: Coated area: Base material:

2,850 x 1,300 mm *) 3.70 m² S235, S355, S690QL (others on request)

Chemical composition 1st layer (wt-%): Fe

Cr

Nb

C

Carbide content

Balance

24.8

4.3

4.8

~ 58

Hardness of the weld material: Maximum working temperature:

approx. 61 HRC approx. 350 ° C

Advantages of DURMAT®–CP 1000 st

-

Complete analysis even in the 1 layer High protection for many wear mechanisms High deformability, the plates can be cut via plasma Easy weldable base material

*) Further plate dimensions on request

DURMAT®

CP 1100 FeCrC-complex carbide wear plate

General characteristics: ®

DURMAT –CP 1000 is a composite hardfacing plate consisting of a weldable steel plate and a wear resistant coating, which offers high wear protection against abrasion and moderate impact and impinging load. The coatings are temperature resistant up to 650°C as well as qualified for corrosion protection. The coating of a C-Cr-alloy with additional incorporated complex carbides of the type CrC, VC, MoC, WC and MoC is related to the alloy group Fe16 according to EN 14700 (group 10 former DIN 8555). Applications: Steel fabrication, fans in the hot gas area, foundries Technical data: Plate dimensions: Coated area: Base material:

2,850 x 1,300 mm *) 3.70 m² S235, S355, S690QL (others on request)

Chemical composition 1st layer (wt-%): Fe

Cr

Nb

Mo

W+V

C

Carbide content

balance

22

4.7

4.8

2.5

4.85

60

Hardness of the weld material: Maximum working temperature:

approx. 62 HRC approx. 650° C

Advantages of DURMAT®–CP 1100 -

st

Complete analysis even in the 1 layer High protection for many wear mechanisms High deformability, the plates can be cut via plasma Easy weldable base material

*) Further plate dimensions on request

DURMAT®

CP 1168 FeCrCB-complex carbide wear plate

General characteristics: ®

DURMAT –CP 1168 is a composite hard-facing plate consisting of a weld able steel plate and a wear resistant coating, which offers high wear protection against abrasive wear and moderate impact. The coatings are temperature resistant up to 800°C as well as conditionally qualified for corrosion protection. The coating of a C-Cr-B-alloy with additional is related to the alloy group T Fe15 according to EN 14700 (group 10 former DIN 8555). Applications: Steel fabrication, fans in the hot gas area, foundries, mining, and parts subject to high temperature in steel work application. Technical data: Plate dimensions: Coated area: Base material:

2,850 x 1,300 mm *) 3.70 m² S235, S355, S690QL (others on request)

Hardness of the weld material: Maximum working temperature:

approx. 62 – 68 HRC at 20 ° C approx. 800° C

Advantages of DURMAT®–CP 1168 -

High temperature resistant High resistances against many wear mechanism.

-

*) Further plate dimensions on request

DURMAT®

CP 1175 Fe-based complex carbide wear plate

General characteristics: ®

DURMAT –CP 1175 is a complex carbide wear plate. The microstructure is showing a high volume fraction of ultra hard complex carbides in combination with borides. This results in an exceptional resistance to wear, erosion and abrasion.

Advantages: Low coefficient to friction without lubrication for metal-to-metal action. Improved impact resistances compared to other hard-faced wear plates.

Technical data: Plate dimensions: Coated area: Base material:

2,850 x 1,300 mm *) 3.70 m² S235, S355, S690QL (others on request)

Hardness of the weld material:

approx. 68 HRC at 20 ° C

Advantages of DURMAT®–CP 1175 -

High wear-, erosion-, and abrasion resistant Excellent friction coefficient

-

*) Further plate dimensions on request

DURMAT®–PLATINUM-WEAR PLATES The PLATINUM plate, fabricated with the high performance welding process PTA (Plasma Transferred Arc), is the answer to the increasing demands to improve profitability and productivity in the heavy industry where we are able to apply special Iron based alloys. Primary carbides in combination with Ni-, Co and Fe based alloys improve the wear resistance significantly, compared with conventionally welded Cr-carbides. High wear resistant Fused Tungsten Carbides (FTC) in combination with a Ni-alloy offer excellent protection against sliding, grooving and rolling wear. The Ni-based alloy offers exceptional properties for temperatures up to 500°C. The PTA process features a metallurgical bond with a dilution limited to 5 – 10%. A further advantage is the fabrication of thin wear plates which can be used to manufacture weight optimized protective components (e.g. fan blades) Typical / standard dimensions: Base material

Coating

Total

Weight

(mm)

(mm)

(mm)

(kg/m²)

3

3

6

62

4

3; 4; 6

7; 8; 10

69; 82; 106

5

3; 4; 6

8; 9; 11

77; 90; 115

6

3; 4; 6

9; 10; 12

85; 98; 128

8

3; 4; 6

11; 12; 14

101; 114; 139

10

3; 4; 6

13; 14; 15

117; 130; 155

Plate thickness: Plate dimensions: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness: Plate dimension: Coated area:

4, 5, 6, 8; 10 mm (alternatively other plate thickness on request) 2,500 x 1,250 mm *) 2,300 x 1,100 mm *)

Thinnest coating:

2 mm ± 0.5 mm

*) Further dimensions on request or related to specification demands

Delivery form: DURMAT- CP – plates can be delivered as pre-finished blanks with fixation elements, sinkhole bores or others. Recoating is carried out with similar alloy electrodes (DURMAT NISE) or core wires (DURMAT NIFD). Typical carbides: TiC; VC; NbC; Cr3C2; FTC, WC, WC/Co; WC/Ni; Carbide content and distribution related to different physical properties such as density and melting point are widely controllable. This is mainly because of the application and development for the components of the plasma torch, the powder feeder as well as the development of the welding parameters based on the internal Know-How of DURUM GmbH. Applications: Fan components, conveyor and separator tubes, coal mills, silo coatings, cement fabrication, concrete mixer, grit blasting components, exhaust filters and cyclones, crusher and mill coatings, combustion components, power plants and others. DURMAT®–PLATINUM–microstructure, 1st layer

45 40 35 30 25 20 15 10 5 0

40

11,9 11,8 9 2

4,3

IS E N

N IF 10 D 61 W 10 P 62 W P

ar d

S2 35 ox 40 M 0 et al A rc

1

H

Wear factor

DURMAT®–1061 WP

Rubber wheel wear test ASTM G65-00

DURMAT®–1062 WP

DURMAT®

1061 WP PTA-wear plate

Properties: ®

DURMAT –1061 WP is a composite hardfacing plate consisting of a weldable steel plate and a wear resistant coating. The hardfacing layer consists of a Ni-B-Si matrix alloy with embedded Fused Tungsten Carbide (FTC). The Chromium free alloy enables higher hardness compared to the M7C3 type and comprises higher matrix hardness. The incorporated FTC offers a specific hardness larger than 2.340 HV0.1. The low melting point of the matrix alloy, as well as the plasma processing of the composite material, enables a metallurgical bonding to the base material and a minimized dilution. Application: To be applied to sliding, grooving, rolling impact wear; superior properties for temperatures up to 500°C. Technical data: Plate thickness: Plate dimensions: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness:

4, 5, 6, 8 mm Other thicknesses on request. 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm 54 - 57 HRC 2,340 HV0.1

Plate dimensions: Coated area: Minimum coating thickness: Hardness of the weld material: Hardness of the FTC: Base material:

S235, S355, S690QL, 1.4304, 1.4828 (others on request)

Advantages of DURMAT®–1061 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight, enables high rotation speed of fans High formability, the plates can be cut via plasma Easy weldable base material

*) Further plate dimensions on request

DURMAT®

1062 WP PTA-wear plate

Properties: ®

DURMAT –1062 WP is a composite hardfacing plate consisting of a weldable steel plate and a wear resistant coating similar to the 1061 WP. Contrary to the 1061 WP Spherical Fused Tungsten (DURMAT-SFTC), carbide particles are embedded into a Ni-B-Si matrix to achieve a high performance wear resistance coating. SFTC is known as one of the hardest and most wear resistant materials and achieves hardness values over 3000 HV0.1. The low melting point of the matrix alloy, as well as the plasma processing of the composite material enables a metallurgical bonding to the base material and a minimized dilution. Application: To be applied to sliding, grooving, rolling impact wear; superior properties for temperatures up to 500°C. Technical data: Plate thickness: Plate dimesnion: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness: Plate dimension: Coated area: Minimum coating thickness: Hardness of weld material: Hardness of FTC:

4, 5, 6, 8 mm, other thicknesses on request 2.500 x 1.250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm 54 - 57 HRC 2,340 HV0.1

Base material:

S235, S355, S690QL, 1.4304, 1.4828 (others on request)

Advantages of DURMAT®–1062 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight enables high rotation speed of fans High formability, the plates can be cut via plasma Easy weldable base material

*) Further plate dimensions on request

DURMAT®

1071 WP PTA-wear plate

Properties: ®

DURMAT –1071 WP is a composite hard-facing plate consisting of a weld able steel plate and a wear resistant coating. The hard-facing layer consists of a Ni-Fe matrix alloy with embedded Fused Tungsten Carbide (FTC). The incorporated FTC offers a specific hardness higher than 2.340 HV0.1. Excellent wear and erosion resistance especially designed for Fans. Application: To be applied to sliding, grooving, rolling impact wear, superior properties for temperatures up to 500°C. Technical data: Plate thickness: Plate dimensions: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness:

4, 5, and 6, 8 mm Other thicknesses on request. 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm 54 - 57 HRC 2,340 HV0.1

Plate dimensions: Coated area: Minimum coating thickness: Hardness of the weld material: Hardness of the FTC: Base material:

S235, S355, S690QL, 1.4304, 1.4828 (Others on request)

Advantages of DURMAT®–1071 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight enables high rotation speed of fans High formability, the plates can be cut via plasma Good ratio in between price and performance

*) Further plate dimensions on request

DURMAT®

1072 WP PTA-wear plate

Properties: ®

®

DURMAT –1072 WP is a composite hard-facing similar matrix composition as DURMAT –1071 WP. The hard-facing layer also consists of a Ni-Fe matrix alloy but with embedded Spherical Fused Tungsten Carbide (SFTC). The incorporated SFTC offers a specific hardness of approx > 3,000 HV0.1. Much better performance compared to regular Wear Plates subject to erosive wear. Application: To be applied to sliding, grooving, rolling impact wear, superior properties for temperatures up to 500°C. Better erosion wear. Technical data: Plate thickness: Plate dimensions: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness:

4, 5, and 6, 8 mm Other thicknesses on request. 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm 54 - 57 HRC 2,340 HV0.1

Plate dimensions: Coated area: Minimum coating thickness: Hardness of the weld material: Hardness of the FTC: Base material:

S235, S355, S690QL, 1.4304, 1.4828 (Others on request)

Advantages of DURMAT®–1072 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight enables high rotation speed of fans High formability, the plates can be cut via plasma Good ratio in between price and performance

*) Further plate dimensions on request

DURMAT®

1073 WP PTA-wear plate

Properties: ®

DURMAT –1073 WP is a composite hard-facing plate consisting of a weld able ferrite steel plate and a combined good wear and limited corrosion resistant overlay. The hard-face coating consists of a Ni-Fe alloy reinforced with monocrystalline tungsten carbides (MTC). Mono tungsten carbides have good compatibility with nickel making them very suitable for use as a hard phase component in the PTA process. No phase transformation occurs in the molten metals during the PTA process; thus, no embitterment of the matrix metal occurs.

Application: To be applied to sliding, grooving, rolling impact wear, superior properties for temperatures up to 500°C. Technical data: Plate thickness: Plate dimension: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness: Plate dimension: Coated area: Minimum coating thickness:

4, 5, 6, 8 mm, other thicknesses on request 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm

Base material:

S235, S355, StE 690, 1.4304, 14828 (Others on request)

Advantages of DURMAT®–1073 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight enables high rotation speed of fans High formability, the plates can be cut via plasma Easy weld able base material

*) Further plate dimensions on request

DURMAT®

1074 WP PTA-wear plate

Properties: ®

DURMAT –1074 WP is a newly developed composite wear plate consisting of a special matrix alloy reinforced with fused tungsten carbides (FTC) as well as very hard and extremely wear resistant special carbides. DURMAT®–1074 WP offers a very good combination of temperature and abrasion resistance.

Application: Especially designed for applications such as mining-, ceramic-, as well as austenitic and ferritic parts. Technical data: Plate thickness: Plate dimension: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness: Plate dimension: Coated area: Minimum coating thickness:

4, 5, 6, 8 mm, other thicknesses on request 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm

Base material:

S235, S355, StE 690, 1.4304, 14828 (Others on request)

Advantages of DURMAT®–1074 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction High formability, the plates can be cut via plasma Easy weld able base material

*) Further plate dimensions on request

DURMAT®

1401 WP PTA-wear plate

Properties: ®

DURMAT –1401 WP is a composite hardfacing plate consisting of a weldable ferritic or austenitic steel plate and a combined wear and corrosion resistant coating. The hardface coating consists of corrosion resistant NiCrMo-alloy reinforced with FTC. The Mo- and Cr matrix alloy allows the application even under corrosion loads up to working temperatures of 600°C. The reinforcing FTC reveals hardness larger than 2,340 HV0.1. By the use of the unique PTA system, a metallurgical bonding to the base material and a minimized dilution is achieved. Application: To be applied to sliding, grooving, rolling impact wear; superior properties for temperatures up to 600°C, good corrosion resistance Technical data: Plate thickness: Plate dimension: Coated area:

3 mm 2,000 x 1,000 mm *) 1,800 x 800 mm *)

Plate thickness: Plate dimension: Coated area: Minimum coating thickness:

4, 5, 6, 8 mm, other thicknesses on request 2,500 x 1,250 mm *) 2,300 x 1,100 mm *) 2 mm + - 0.5 mm

Base material:

S235, S355, StE 690, 1.4304, 14828 (others on request)

Physical properties: Hardness of FTC: Hardness weld material:

2,340 HV0.1 54 - 57 HRC

Advantages of DURMAT®–1401 WP -

Low grade of dilution with the base material (5-10 %) Dense surface, low coefficient of friction Low weight enables high rotation speed of fans High formability, the plates can be cut via plasma Easy weldable base material

Patents: No. 4008091.9-41, Nr.299 18 960.0 *) Further plate dimensions on request

DURMAT®–CP - PLATE and PLATINUM-PLATE Wear to technical surfaces need an intensive analysis in order to improve their life and enhance productivity and profitability. We rely on over 25 years of experience in the development, production and distribution of wear protection products. Our goal to meet customer requirements is subsequently based on cooperation with established research institutes, which is the basis for the choice and application of DURUM products. Ductile, often eutectic Hard particle type: , Me7C solidified matrix

Influencing facAmount of hard particles tors Character of hard particels Size of hard particles Composition of the matrix Bonding to the matrix Line spacing

Fe-based hardfacing alloy related to group Fe14 EN 14700 (group 10 former DIN 8555)

Ni-based hardfacing DURMAT® NIFD

45 40 35 30 25 20 15 10 5 1 0

40

11,8 2

2,3 2,96

4,3

S2 H ar 35 do C hi lle x 4 00 Fu d c as rn tin ac g e br az in g M et al A rc 10 61 W P 10 62 W P

service life time factor

.

The resulting component lifetime is the key to the successful realization of modern maintenance tasks with respect to ecological aspects. Specific, international standardized wear tests show the superior resistance of our CP-PLATE and PLATINIUM-wear protective solution which enables the increased availability of components based on a reduction of maintenance costs.

service life time factor .

Rubber wheel test (ASTM G65-00) *)

8 7 6 5 4 3 2 1 0

Sliding erosion

Angular erosion

Impingin erosion

Jet angle

Jet angle

Jet angle

4.65

1

S235

1.1

Metal Arc

Erosion wear – jet angle 30°

*) ISAF, TU Clausthal

1061WP

Wear Caused by Mineral Abrasion 1. Three body abrasion wear areas*

2. Two body abrasion wear areas*

3. Abrasion caused by stream particles *

*) ISAF, TU Clausthal

Examples of Successful Industrial Application