CLADDING TECHNOLOGY SHANXI CO., LTDApplication of High-Frequency Overlay Lining Plate on Feeder Equipment
Literature Overview
This 2009 research paper by Wu Zhenqing, Wang Zanbin, and Hou Jiancheng from the School of Materials Science and Engineering at Zhengzhou University presents the application of high-frequency overlay lining plates on feeder equipment in mining operations. Published in Mining Machinery, this work addresses the practical challenge of extending the service life of feeder components subjected to severe abrasion from mineral particles in bulk material handling systems.
Core Technical Analysis
Feeder equipment in mining operations handles large volumes of abrasive materials such as coal, iron ore, copper ore, and aggregate. The lining plates that protect the feeder body from abrasion are subject to continuous impact and sliding wear from mineral particles. Conventional carbon steel lining plates typically require replacement every 3-6 months, resulting in significant downtime and material costs.
| Component | Material | Service Life (Uncladded) | Function |
|---|---|---|---|
| Feeder body | Q235 or Q345 | 5-10 years | Structural support |
| Lining plate (original) | Q235 | 3-6 months | Abrasion protection |
| Lining plate (cladded) | Overlay cladding | 18-36 months | Enhanced abrasion protection |
| Wear strips | Hardfacing | 12-24 months | Impact protection |
| Side plates | Carbon steel | 1-2 years | Material containment |
The high-frequency overlay lining plate technology involves:
- Applying a transition layer to ensure metallurgical compatibility
- Depositing multiple passes of wear-resistant overlay material
- Achieving a total overlay thickness of 3-8 mm depending on service conditions
- Ensuring uniform hardness distribution across the plate surface
- Maintaining adequate bond strength between the overlay and base plate
Overlay Material Selection and Properties
The selection of overlay material depends on the specific abrasion mechanism and service environment:
| Overlay Type | Composition | Hardness (HV) | Wear Resistance | Application |
|---|---|---|---|---|
| Iron-based carbide | Fe-5Cr-3Mo-2.5C | 600-700 | Excellent | Coal feeders |
| Iron-based chromium | Fe-12Cr-2Mo-1C | 500-600 | Good | Iron ore feeders |
| Nickel-based | Ni-20Cr-5Mo | 400-500 | Moderate | Wet conditions |
| Copper-based | Cu-10Sn-5P | 200-300 | Poor | Not recommended |
| Austenitic | Fe-18Cr-8Ni-2Mo | 250-350 | Moderate | Corrosive environments |
For most mining feeder applications, iron-based carbide overlay materials provide the best combination of wear resistance, cost-effectiveness, and weldability. The high carbon and chromium content promotes the formation of hard carbides (M7C3 and M23C6) that provide superior abrasion resistance.
Process Parameters and Quality Control
The high-frequency overlay process for feeder lining plates requires careful parameter control:
| Parameter | Typical Value | Quality Impact |
|---|---|---|
| Welding current | 280-380 A | Penetration and dilution |
| Arc voltage | 24-32 V | Bead profile and uniformity |
| Travel speed | 0.2-0.4 m/min | Layer thickness |
| Wire diameter | 1.6-2.4 mm | Deposition efficiency |
| Overlap ratio | 60-70% | Complete coverage |
| Interpass temperature | 80-150 °C | Crack prevention |
| Number of passes | 4-8 | Achieve target thickness |
Quality control procedures include:
- Visual inspection for surface defects (cracks, porosity, undercut)
- Magnetic particle testing for surface and near-surface cracks
- Hardness testing to verify uniform hardness distribution
- Bond strength testing to ensure adequate adhesion
- Wear testing to verify performance improvement
- Dimensional inspection to ensure plate geometry
Performance Evaluation and Economic Analysis
Field trials of high-frequency overlay lining plates on feeder equipment have demonstrated significant improvements in service life:
| Application | Original Life | Cladded Life | Improvement Factor |
|---|---|---|---|
| Coal feeder | 4 months | 24 months | 6x |
| Iron ore feeder | 3 months | 18 months | 6x |
| Aggregate feeder | 5 months | 30 months | 6x |
| Slurry feeder | 3 months | 15 months | 5x |
The economic benefits include:
- Reduced downtime for lining plate replacement
- Lower material consumption for new plate fabrication
- Extended maintenance intervals
- Improved operational safety through reduced unplanned stops
- Reduced overall cost per ton of material processed
Study Insights and Reflections
This research demonstrates the practical value of weld overlay technology in extending the service life of mining equipment components. The high-frequency overlay lining plate approach provides a systematic methodology for addressing the fundamental challenge of severe abrasion in bulk material handling systems.
From a metallurgical perspective, the multi-pass overlay strategy with transition layers ensures adequate bond strength and crack resistance. The process design allows for consistent parameter control, which is essential for achieving uniform overlay properties across the entire plate surface.
In conclusion, the application of high-frequency overlay lining plates on feeder equipment provides an effective, economical solution for extending the service life of mining equipment, and its successful implementation demonstrates the versatility of weld overlay technology in addressing industrial wear challenges in bulk material handling operations.