Wear Resistant Tiles

Abrasive materials and bulk material movement, which involves sliding over surfaces, very often causes heavy wear on the equipment used, resulting in:

  • Damage to equipment.
  • Lower Reliability.
  • Production Losses.
  • Lower Capacity Utilization.

Having Walker Services install some premium wear resistant tiles, which is discussed below can be a solution. In fact a necessity, in today’s competitive environment, equipment availability and low operating costs are essential. Allow Walker Services to help your machine run more efficiently and more often.

Tungsten Carbide Tile

WEAR PROOFING

Superior surface protection against wear. Brazed parts can withstand extreme heat up to 800 °F. Braze tensile strength can meet or exceed the strength of the parent metal. Cuts repair cost and downtime substantially, while adding a longer life to present equipment. Withstands impact and abrasion, maintenance cost is virtually eliminated. Corrosion resistant. Pays for itself in reduced labor / change-out time.

BRAZED TUNGSTEN CARBIDE FEATURES

In most cases, it is either too expensive or technically impossible to make a large part from solid tungsten carbide, so most parts are composites of carbide tiles attached to a steel base. Additionally, as an unweldable material that resists most conventional attachment methods, carbide is difficult to work with. The best way to attach carbide is by silver solder brazing. Using primarily induction brazing, we form a strong structural bond which supports the carbide and keeps it securely in place in the appropriate wear areas. After carbide is properly installed, it can be expected to outlast steel by as much as 50 to 1. There are no additional “build-up” treatments or procedures required. Special carbide grades can be applied where higher impact resistance, wear resistance or more corrosion resistance is required. Various Tungsten carbide grades are produced to protect against a spectrum of wear problems, ranging from “soft” Impact grade to “hard” wear resistant grades. Generally carbide harness trades off against impact resistance. The objective in a carbide application is to use the hardest grade that will not break. The softest impact grade carbide grade has approximately the same hardness as the hardest tool steels. Since “softness” is related to abrasion resistance. Impact grade carbide starts where steel’s abrasion resistance stops. “Hardness” is a good indication of abrasion resistance, it can also be used for an application guideline. Tungsten carbide ranges in hardness from a “soft” 68 Rockwell C scale for impact grades to 93 Rockwell A scale for the hardest wear resistant grades.

TUFFCARB OPTION

    • This process introduces solid tungsten carbide shapes into a hard-facing weld matrix. The resulting product has wear characteristics of solid tungsten carbide with increased shock resistance. TuffCarb works well in heavy impact situations, buckets, loaders, etc.

TIGERCARB OPTION

    • This proprietary process which injects carbide powders into a plasma stream. This product has many of the wear characteristics of solid tungsten carbide, plus the ability to conform to corners and curved shapes and corrosion resistance. TigerCarb also works well in heavy impact and with rough particulate abrasion.

CERAMIC TILES

The vacuum bonding process results in a 5000 PSI minimum composite bond strength between the ceramic and the base metal. This bond is tested for every batch. For even wear and uniform weight distribution a fine grain aluminum ceramic with an average grain of 4 microns is utilized.

STEEL-RAMIC vacuum bonded tile is widely suited for wear protection of moving parts and areas subjected to impact. Standard tile sizes are 1” x 1” with thickness of 1/8”, 3/16”, and 1/4”. Smaller tiles are used when necessary to minimize chords on small curved surfaces. Use of small thin aluminum ceramic tiles improves impact resistance and eliminates tile cracking / spalling due to substrate flexing and twisting.

For areas with usual impact or extreme wear, tungsten carbide tiles can be overlaid or ceramic can be applied directly to the metal base. This process takes much effort to conceive the increase in pricing vs wear ability.

Suitable for applications with maximum continuous operating temperatures of 250°F (standard) and 350°F (high temperature).

The use of the vacuum bonding process along with small, thin, ceramic tiles permits lining of complex, internal / external geometry’s, compound curved surfaces. Shop installation typically required for lining small component parts up to 6 cubic feet. Larger components can be lined using segmented bolt-in panels.

WELDABLE ENGINEERED TILE

TYPICAL PROPERTIES

In the service of high abrasion and less impact the solid weldable ceramic tile is the product of choice.

MOH HARDNESS CHART

DIAMOND ARLCITE AL. OXIDE TOOL STEEL SILICA
10.0 9.0 6.5 6.0
GLASS CARBON STEEL COPPER N/A
5.5 5.5 3.0 N/A

MOH HARDNESS CHART

STEEL RAMIC A STEEL RAMIC E
Nominal Alumna 85% 98%
Water Absorption 0% 0%
Density 0.1227 lbs/in 3 225 lbs/ft 3
Compressive Strength 180,000 PSI 419,950 PSI
Flexural Strength 39,000 PSI 40,800 PSI
MOH Hardness 9 9

Walker Services Steel-Ramic products are resistant to wear from all materials except for diamonds.
Installation can be accrued by adhesives, welding, bolting and studs.
Special engineered tiles can be supplied as well as standard sizing.
In addition, a complete fabrication or re-work project can be lined with Steel-Ramic products.

Allow walker services to cast or fabricate your consumable wear part and wear proof with our products.