CLADDING TECHNOLOGY SHANXI CO., LTDApplication Status and Development Prospects of Wear-Resistant Cladding Materials in the Cement Industry
Literature Overview
Published in 2009 by Wei Jianjun, Pan Jian, Huang Zhiquan, Xu Jian, and Wang Xin of Zhengzhou Machinery Research Institute, this paper examines the application of wear-resistant cladding materials in the cement industry. The cement industry is one of the most demanding environments for wear-resistant surfaces, with equipment subjected to abrasive particles, chemical attack, and high-temperature exposure simultaneously. This work provides a practical assessment of cladding technology applicability in a heavy industrial setting.
Core Technical Content
The paper surveys the types of wear-resistant cladding materials used in cement plant equipment, including high-chromium cast irons (Cr20, Cr26, Cr30), medium-alloy steels with carbide-forming elements, and specialized overlay alloys containing tungsten carbide (WC) or chromium carbide (Cr7C3) particles. The cement industry applications covered include grinding mills (ball mills, roller mills), conveyors, hoppers, chutes, preheater tower internals, and kiln wear plates.
| Application Area | Wear Mechanism | Recommended Cladding Material | Typical Service Life Improvement |
|---|---|---|---|
| Ball mill liners | Abrasion + impact | Cr20 high-chromium iron, Ni-hard alloy | 2–4× base material |
| Roller mill grinding table | Abrasion | WC-cermet composite overlay | 3–5× base material |
| Conveyor chutes | Abrasion + erosion | Cr26 high-chromium iron | 2–3× base material |
| Hopper walls | Abrasion + impact | Hardfacing steel (Fe-Cr-C type) | 2–4× base material |
| Preheater tower internals | Abrasion + corrosion | Cr-Ni austenitic alloy | 3–6× base material |
Process Selection for Cement Industry Applications
The paper discusses the selection of cladding processes appropriate for cement industry applications. Submerged arc welding (SAW) is preferred for large, flat surfaces such as mill liners and hopper walls due to its high deposition rate and good productivity. Gas metal arc welding (GMAW) and flux-cored arc welding (FCAW) are used for smaller components and repair work where flexibility is required. For in-situ repair of operating equipment, portable SAW or GMAW systems are commonly deployed. The paper also addresses the challenges of cladding on heavily deformed or work-hardened substrate surfaces, which are common in cement plant components that have been subjected to repeated impact loading.
A critical aspect discussed is the residual stress and cracking susceptibility of wear-resistant cladding deposits. High-carbon, high-chromium deposits are prone to cold cracking due to the formation of hard martensite during cooling. The paper recommends preheating substrates to 200–300°C, maintaining interpass temperatures at 150–250°C, and applying post-weld heat treatment at 550–650°C for stress relief and microstructure refinement. For applications where PWHT is impractical, the use of nickel-based or austenitic transition layers between the substrate and the wear-resistant deposit is recommended to reduce cracking susceptibility.
Engineering Practice Considerations
The cement industry presents unique challenges for cladding applications that differ from those in the petrochemical or nuclear industries. Equipment is often operated in dusty, high-vibration environments, and maintenance windows are limited to scheduled shutdowns. This necessitates cladding procedures that are robust, repeatable, and amenable to rapid field application. The paper advocates for the development of standardized cladding procedures for common cement industry components, enabling maintenance teams to perform repairs without requiring specialized welding engineers on site.
The economic analysis presented in the paper demonstrates that wear-resistant cladding can extend component service life by 2 to 6 times compared to unclad or simply replaced components, with a payback period typically less than 12 months. This economic argument is particularly compelling for large components such as mill liners and preheater tower internals, where replacement costs are substantial and downtime is extremely expensive.
Study Insights and Reflections
This paper represents a practical, industry-focused assessment of cladding technology that complements the more academic and standards-oriented literature. Its emphasis on economic justification and practical applicability makes it particularly valuable for engineers who must make procurement and specification decisions. The identification of specific material-process-application combinations for cement industry components provides a useful reference framework that can be adapted to other abrasive-wear industries such as mining, power generation, and aggregate processing. The paper also highlights the importance of considering the entire lifecycle of a cladded component, from initial fabrication through multiple repair cycles, which is a perspective often overlooked in purely technical evaluations.