10.09.2018

Durit Hartmetall GmbH

Investing for saving.

Wear protection pays off.
The costs are huge. Economies all over the world have to bear the consequences of wear, corrosion, and mechanical load in the amount of two to five per cent of the gross domestic product. The loss just in Germany runs into high two-digit billions.

By now, there is no way around active wear protection in many sectors, since the use of recent research findings and innovative technology may help saving a lot of money. Starting with consumption of material and energy via production costs to expenditures on maintenance and technical services.

But due to global competition, the Olympic maxim is still valid: faster, higher, further. However: Intensified process conditions and the demand for increasing quantities cause a disproportional progression of wear related to machines and components. This development is individually amplified by the use of particularly abrasive substances.

High-tech quality tungsten carbide
In order to achieve maximum efficiency, faster lead times, and preferably long service lives, production systems have to be optimized and updated. At the same time it is necessary to significantly increase the load capacity in continuous operation. Tungsten carbide proves successful in this connection. The sintered materials made of tungsten carbide combined with an appropriate binder adjusted to each kind of application offer advantages especially relevant in high-performance production. These include enormous wear and pressure resistance, exemplary resilience towards abrasion, electric conductivity, low fracture susceptibility as well as chemical and thermal stability. That means: Tungsten carbide lasts considerably longer – even under extreme conditions in a rough environment.

DURIT Hartmetall GmbH provides a practical example from petrochemistry: When separating solids from quench oil, the load on the components in the lower part of a hydrocyclone separator is extremely high due to high flow velocities. Hence, the use of GD10, a highly abrasion-resistant sort of tungsten carbide, made this area resistant to wear. Moreover, the experts decided to assemble the separation valve with this exceptionally hard tungsten carbide quality, which is also dimensionally stable especially in the sealing area. The additional costs arising from the use of tungsten carbide amortized within a few month due to a considerably higher service life of the hydrocyclone.

A range with profitable possibilities
Due to the positive experience with the use of tungsten carbide in production processes, more and more users proceed to replace tools and elements exposed to wear by resilient parts made of tungsten carbide.

But this complete replacement is not the only investment opportunity for sustainable wear protection. The company DURIT from Wuppertal shows that there are also other opportunities to effectively avert detrimental influences in industrial production. And indeed, in a cost-efficient way.

Thus, DURIT does not only offer components and precision tools made of customized tungsten carbide varieties, they also develop component coatings made of other, often inferior materials. The result is surprising. These high-quality wear protection layers significantly improve the properties of the basic material. This optimization process makes the respective component overall much more stable and durable.

In order to constantly find the best solution for the use of tungsten carbide, this company from the Bergisch Land consistently focuses on a large variety. The experts provide a range of about 60 different sorts of tungsten carbide of their own development as a broad basis for a customer-specific material composition.

Another interesting option for a highly efficient wear protection is the combination of tungsten carbide components with coated parts made of steel, aluminium, or cast iron as well as suitable synthetics. This easily works out. Tungsten carbide firmly and safely adheres to the substrate – if attached by gluing, soldering, shrinking, casting, or by a mechanical friction-locked attachment. Certainly, the best choice of attachment is principally dependent on the field of application the piece is used in. One thing is for sure: Since only heavily loaded surface areas of the components are made of sheer tungsten carbide, maintenance costs are decreased in the long run.

After all, repairing used and worn components is also worth considering. Correspondingly, wear-resistant coatings may quickly prepare the components for long-term use. This reprocessing pays off if the restoration charges range considerably below the price for the replacement of the parts.

Considering total costs
That much is clear: Before investing in effective wear protection, users should carefully look at the total costs. This implies some important questions. At which process step is the use of a particularly resilient material absolutely necessary? Where might be another material more suitable for increasing the resilience of components or elements? When might be a coating of the parts the best choice?

Without a detailed analysis of individual production conditions on site, these key questions may not be answered adequately. One criterion for taking one or another investment decision will always be a cost-efficient relationship between required material, material costs, and service life. With this in mind, the choice of material plays a prominent role.

Exhibitor Data Sheet