Wear analysis Material development Production Application. Made in Germany

Transcription

1 Wear analysis Material development Production Application Made in Germany

2 aerial view of company head quarters Company profile With the foundation of CORODUR VerschleissSchutz GmbH in Thale/Harz in 990, a reliable business partner for wear intensive industries is created. By professional competent technical consultation and problem oriented, innovative development up to usable solutions, we can offer an extensive product range in the field of wear protection. Our customers know to appreciate the concentration of production, service, research and development at one place to solve their wear problems profitably. We offer you: an extensive range of fluxcored wires for hardfacing by welding, spraying and gasshielded arc brazing powder metallurgical sintered stripe eletrodes for SA and REScladding special powders for PTAsurfacing and thermal spraying on iron base hard surfaced wear plates antiwear constructions hardfacing service for repair and new production, including machining flame and arc spraying for surfacing of thin coatings special claddings with high carbidenous special alloys in plasmapowder process In our catalogue you find an overview of our standard product range and and a selection of typical application samples.

3 production hall filling station various forms of delivery transverse section of fluxcored wire machine for fluxcored wire production Fluxcored wire production Summary of product range fluxcored wire work hardening austenitic hardfacing alloys impact resistant hardfacing alloys, tool steel alloys high abrasion resistant hardfacing alloys nickel base alloys, cobalt base alloys chromenickel alloys for corrosion resistant claddings alloys for cast iron cold welding special alloys with tungsten carbides gas shielded arc brazing wires on copper base fluxcored spray wires for surfacing of thin coatings We produce our fluxcored wire electrodes as wire formed from folded stripes in diameter, mm to 4,0 mm for openarc welding, gas shielded welding and submergedarc welding. Depending on alloy type and welding process you can get these wires with slag formation as well as in metal powder characteristic.

4 Overview fluxcored wire electrodes Product name C Si Mn Cr Ni Mo Co Nb V W Fe So. Deposit hardness Corthal 00 K 0, 6 8 8, HB; work hardened 400 HB Corthal 40 K 4 4 0, HB; work hardened 40 HB Corthal 0 K 6 4, 0,6 0 0 HB; work hardened 00 HB Corthal 00 0,, 80 HB Corthal 0, 0, 4 4 HRc Corthal HRc Corthal 6 0, HRc Corthal 400 0,6, 8 4 HRc Corthal 440,, bis 480 HB Corthal 40 4, 0, 4 4 HRc Corthal 476 0,7 6 4, 48 0 HRc Corthal 0 0, 0,,, 48 HRc Corthal 80 0,,,, 48 HRc Corthal 60 0,7 6,, HRc Corthal 600 TiC,8,4 7,4 Ti 6 8 HRc Corthal 600 6, 6 HRc Corthal 60 6,6, 4 8 HRc Corthal 606 0,6 0,9, 4,,6, 7 HRc Corthal 609,7 0,6 9, 7 HRc Corthal 6 0,9,, 4 6 HRc Corthal 6 0,6 0,6 0,6, 8 HRc Corthal , 48 0 HRc Corthal WZ 0 0, 0,9 0,7, 0,6 4, 48 0 HRc Corthal WZ 0,, 0,9, 0, 7 6 HRc Corthal WZ 9 0,6, 4,, 7 9 HRc Corthal WZ 66 0,0 8 4 Ti ca. HRc; hardened to HRc Corthal 4,8 0,9, HRc Corthal 0,8,8 0 4 HRc Corthal 4,8, 8 B 9 HRc Corthal Mo,7 0, 7, 7 60 HRc Corthal 6, 0, HRc Corthal 9, 9 6 HRc Corthal 9L,7, 6 9 HRc Corthal 60,4, 0, HRc Corthal 6,4,6 7 B 6 6 HRc Corthal 6,, 0, HRc Corthal 64,8, B, HRc

5 Overview fluxcored wire electrodes DIN 8 DIN EN 4700 Type (ø in mm) Main applications AlloyNo./AWS OA G SA MF 800CKNPZ T Fe 000CKNPZ,,8 see Corthal 470 austentic, work hardening, buffer layer, MF 70KNP T Fe 90KNP,6,8,,6 impactproof, frogs, coarse crusher, MF 70KNP T Fe 90KNP,,,,4,4 4,0 crusher jaws, rolls, rails, beaters MF 00P T Fe 00P,6,8,,4,4 4,0 cable rolls, shafts, wheels, build up welding MF 4PRT T Fe 74PRT,,6,4 4,0 continuous casting rolls MF 0PT T Fe 80PT,4 4,0 back up rolls, shafts MF 40CPT T Fe 740CPT,6,4,,6,4 4,0 continuous casting rolls MF 40P T Fe 40P,6,8,,6,4 4,0 auxiliary rolls, guilding rolls MF 40PRT T Fe 840PRT,4 4,0 hot strip mill table rolls, pinch rolls MF 4PT T Fe 4PT,6,8,6,4,4 4,0 crane wheels, rails, guilding rolls MF 0PRT T Fe 70PRT,,6,4 4,0 steel mill rolls MF 60PRT T Fe 80PRT,4 4,0 hot hardening treatment, steel mill rolls MF 60PT T Fe 80PT,6,4,,4,4 4,0 hot working tools, guilding rolls MF 60PT T Fe 80PT,,6,4 4,0 blast furnace bells, sealing MF 660GP T Fe 860GP,,8 cement crusher rolls MF 6PT T Fe 8PT,6,8,,4,4 4,0 dredging parts, gravel pumps, blowbars MF 660PT T Fe 660PT,6,8,,4,4 4,0 screws, crusher hammers, drive tumblers, MF 6P T Fe 8P,6,8,6,4,4 4,0 road constructions, bucket teeth, MF 6RP T Fe 8RP,,8,,4 rock processing and recycling MF 6RP T Fe 8RP,6,8,,4,4 4,0 suction dredger, gravel pumps, valves MF 660PT T Fe 660PT,,6,4 4,0 blooming and slabbing mill rolls MF 60PRT T Fe 90PRT,6,8,6,4 see 4 mixer paddles, corrosion resistant MF 0ST T Fe 0ST,6,8,,4,4 4,0 mandrel, upsetting die forging tools. MF ST T Fe ST,6,8,,4,4 4,0 hot shear blades MF 4ST T Fe 4ST,6,8,,4,4 4,0 hot and cold working tools.66.66,6,4 Alindustry, Alpresser die casting MF 04CGT T Fe 44CGT,,6,,4,4 4,0 chemical industry, palm oil screws MF 00G T Fe 60G,6, trash crushing, impact resistance MF 060GR T Fe 60GR,,,4 4,0 pumps, mixer parts, conveyer screws MF 060G T Fe 60 G,6, crusher rolls, coal crusher cones, liners MF 06GR T Fe 6GR,6, wear plates MF 060GR T Fe 460GR,, pumps, impeller screws, track hoppers MF 060CGT T Fe 460CGT,,,,,4 4,0 palm oil screws, conveyer screws MF 060G T Fe 60G,, steel, coal, cement and mineral industry MF 06G T Fe 6G,, fan blades, excavator scoops, bucket lips MF 060G T Fe 60G,6, wear plates, pelletizer, rollermill table MF 06GZ T Fe 66GZ,, cement, mineral and brick industry 4

6 Overview fluxcored wire electrodes Product name C Si Mn Cr Ni Mo Co Nb V W Fe So. Deposit hardness Corthal 6,, 0, HRc Corthal 66 4, 9 0, B, HRc Corthal HRc Corthal 68 8 B, HRc Corthal 69, 0,7 0,,, B, HRc Corthal 70,, 0, HRc Corthal 7, 0, 9 B, 60 6 HRc Corthal 7,, 0,6, 4 6,, HRc Corthal 78,, 6 6, 6 B, HRc Corthal 87,, 9 7 B HRc Corthal 70, B 4, HRc Corthal WSCDUR Fe steelmatrix with inserted tungsten carbides ( 8 ) 6 67 HRc; Carbide ca. 400 HV 0.4 Thaloy WSCDUR Ni NiBSimatrix with inserted tungsten carbides ( 68 ) 4 6 HRc; Carbide ca. 400 HV 0.4 Thaloy C 0, HB; hardened 400 HB Thaloy CO 0, 0, 6 6, 0, 4, < HB; hardened 40 HB Thaloy 0 0,0 9 0, HRc; hardened 4 HRc Thaloy 6 0,0, 9 9, < Z70; D0 Thaloy SE / 0, 4, 6 HRc Thaloy SE 6/40 0, 4, 4 4 HRc Thaloy SE /4, < B, HRc Thaloy SE /8 0,7 4,, 60 HRc Corthal NiFe HB Thaloy NiFe 60/ Cu HB Corthal 4009,, 00 0 HB Corthal 40 0,, HB Corthal 408 0, 0,9, HRc Corthal HRc Corthal 4 0,, HRc Corthal 4 0,0 0,9, 4 0,7 8 4 HRc Corthal 470 0,06 0,6 6, 9 8, HB; hardened 400 HB Corthal 449 0, HB Corthal 9/9, HB Corthal SER <0, 4, 4, 8 9, ca. 4 HRc Corthal <0,, 9 B,0 8 4 HRc Thalit 6, 0,6 8 4, <, 40 4 HRc Thalit,4 0, 9 8 <, 4 48 HRc Thalit 0, 7,, <, 0 HRc; hardened 4 HRc

7 Overview fluxcored wire electrodes DIN 8 DIN EN 4700 Type (ø in mm) Main applications AlloyNo./AWS OA G SA MF 06GZ T Fe 66GZ,6, parts in screening units MF 070G T Fe 670G,, bell and chutes, high heat and abrasion resistant MF 06GZ T Fe 66GZ,6, cement and concrete pumps, slurry pumps MF 070CGZ T Fe 70CGZ,6, coke oven screens, pulverizer hammers MF 06GRZ T Fe 6GRZ,6, conctreteindustry, mixer parts, scrapers MF 06G T Fe 66G,6, grinding plant parts, cone crusher MF 06GZ T Fe 66GZ,6, crusher plant parts, sinter wheel breakers MF 06GZ T Fe 66GZ,6, slag conveyer screws, hot sinterbreaker MF 070GZ T Fe 670GZ,6, mining and clinker industry, concrete pumps MF 06RG T Fe 6RG,6, ore dressing tools, rubbermixingblades MF 070G T Fe 70G,6,,,6 wire for welding in one layer MF 6GZ T Fe 06GZ,6,8,6,8 mineral wear, deepwell drilling plant, auger MF CGTZ T Ni 0CGTZ,6,8 highest abrasion resistance, dredger cutter MF 00CKNPTZ T Ni 00CKNPTZ,6,8,4, hot forging die, forging plant parts, hot shear blades, MF 0CKNPTZ T Ni 0CKNPTZ,6,8,4, forging counter die, ~ MF 40CKPTZ T Ni 40CKPTZ,6,8 hot forging hammers ~.46 ~.46,,8 chemical industry, furnace parts MF CTZ T Ni CTZ,6,8 fittings, chemical industry, MF 4CTZ T Ni 4CTZ,6,8 food industry, MF 0CTZ T Ni 0CTZ,6,8 nuclear industry, MF 60CGTZ T Ni 60CGTZ,,8 extrusion screws ~.9 ~.9,,8 cast iron wire for welding GGG. MF NiFe NiFeCi,,8 centrifugal cast iron, tempered cast iron AWS 40 T Fe 8AWS 40,,4,4 4,0 AWS 40 T Fe 8AWS 40,,4,4 4,0 bridge bearings, AWS 40 T Fe 8AWS 40,6,4,4 4,0 sealing surfaces, ~.4 T Fe 8.4,6,4,4 4,0 corrosion, ~.4 T Fe 8.4 see Corthal 64,4 4,0 slide ring sealing, ~AWS 40NiMo AWS 40 NiMo,6,,,4,4 4,0 roller bearings, ~.470 T Fe s. 00 K,,4,4 4,0 centrifuge, valves, AWS 09Mo AWS 09Mo,6,,6,4,4 4,0 continuous casting rolls ~.47 ~.47,,4,4 4,0 special alloy T Fe,6,4,4 4,0 slide ways, sealing surfaces special alloy special alloy,6,4,4 4,0 high corrosion resistance, stellite substitute MF04CTZ T Co4CTZ,,6 armatures, bearing and sliding surfaces, MF 00CTZ TCo0CTZ,,6 hot shear blades, MF00CKTZ TCo0CKTZ,,6 chemical industry 6

8 Overview fluxcored wire for gas metalarc brazing product name Al Ni Fe Mn Si Main application Corthal Lot CuAl8Ni for gas metalarc brazing Corthal Lot CuAl for repair welding at copper alloys with the same com Corthal Lot CuAl8Ni position, also suitable for gas metalarc brazing Corthal Lot CuAl8Ni for brazing of higher strength plate types Corthal Lot CuAlV abrasion resistant hard aluminium bronze Typical compositions of pure weld deposit. Technical modifications reserved. This is only an excerpt from our product range. Other wire compositions according to your specifications can be produced at any time. 7

9 rolling machine sintering furnace delivery form of sintered stripe electrode RESapplication of sintered stripe electrode Sintered stripe electrodes Advantages of sintered stripe electrodes high efficiency of metal deposition with submergedarc and electroslag process wide range of alloys possible adaption of specifications on request economic production also in smaller charges possible availability within a short time exact alloy adjustment 8

10 Overview sintered stripe electrodes Corrosion resistant C Cr Ni Mo Mn Si Nb N Corosint Fe 08 L < Corosint Fe 09 L Corosint Fe 09 MoL Corosint Fe 09 LNb Corosint Fe 6 L Corosint Fe X CrNiMn Abrasion resistant C Cr Ni Mo Mn other Corosint Fe Si 0. Corosint Fe.4 RES Si 0.4 Corosint Fe Si 0. V 0. Corosint Fe W.9 V 0. Corosint Fe 40 NiMo V 0. Nb 0. Corosint Fe 40 MoV V 0. Nb 0.4 Corosint Fe 40 L V 0. Corosint Fe X 8 CrMo / Si 0. Nickel base C Cr Ni Mo Mn other Corosint Ni Nb 0. W.7 Fe 4. Corosint Ni Nb. Ti 0.4 Fe 0.7 Corosint Ni Nb. Fe <.0 Corosint Ni Si 0. Fe Corosint Ni Nb 0. Fe 4. Cobalt base C Cr Co W Mo Si Mn Fe hardness HRc Corosint Co <. 404 Corosint Co 6 LC <. 69 Corosint Co <. 0 Production of special alloys according to your specification possible. Available dimensions: 60 x 0.6 mm (coil weight: max. 6 kgs) 0 x 0.6 mm (coil weight: max. kgs) 9

11 arc spraying transverse section of spray deposit fan wheel flame spraying rotor seals Thermal spraying Thermal spraying with fluxcored wires Our offer optimized fluxcored wire electrodes for arc, flame and highvelocity flame spraying multitude of standard and special alloys in necessary dimensions short term and price favourable production of small amounts and samples development and optimization of spraying materials drawing up of technological solutions for thermal spraying tasks in our own application centre characterization of coatings (metallographic, scanning electron microscope, bonding strength test) 0

12 Overview thermal spraying wires product name C Si Mn Cr Ni Mo Cu Nb V W Fe other Thaloy NiAl 800Sp Al 0 Thaloy NiAl 8 Sp Al Thaloy NiAl 900 Sp Al 0 Thaloy NiAl 9 Sp Al Thaloy NiMoAl 90 Sp Al Thaloy NiCr 800 Sp 0 Thaloy NiCr 4060 Sp 7 Thaloy NiCrFe Sp Thaloy NiCrMo Sp 9 Thaloy CrC Sp Thaloy NiCrBSi Sp B Thaloy SM60 Sp B Thaloy NiWSC Sp 0 WSC B. Thaloy NiCrBSiWSC Sp. 4. WSC B Corthal Sp B Corthal 4 Sp Corthal Sp B 0. Corthal 60 Sp B 0.6 Corthal 6 Sp B 0.6 Corthal CRB Sp B Corthal 00HC Sp Corthal 0 Sp B. ; Ti. Corthal 900 Sp Co.0 Corthal 400 Sp 0. 6 Corthal 4 Sp Corthal X40Cr Sp Corthal NiFe Sp 6 Corthal FeCrAl Sp Al 6 Corthal FeWSC 0. 0 TuC Corthal CuAl9Fe Sp Al 9 Corthal CuAl8Ni6 Sp 6.8 Al 8 Corthal Cu Sp

13 flame spraying Ø.6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;..6;.4;. arc spraying Ø.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4.6;.0;.4 Overview thermal spraying wires Main application bond coat, oxidation resistant bond coat, oxidation resistant bond coat, oxidation resistant bond coat, oxidation resistant selfadhesive spraying material with good impact resistance bond coat for ceramic cover coatings, oxidation and corrosion resistant at high temperatures high oxidation resistance against high temperature corrosion selfadhesive sprayed coatings on high alloyed steels similar to alloy 6, excellent seawater resistance, high oxidation and corrosion resistance wear resistant alloy with good corrosion resistance wear resistant and corrosion resistant protective coatings wear resistant and corrosion resistant protective coatings protection against extreme abrasion, corrosion resistant protection against strong abrasion, corrosion resistant abrasion and corrosion resistant ductile spray coatings with low frictional coefficient good corrosion resistance, for low abrasion attack excellent abrasion resistance with moderate corrosion resistance very high resistance against mineral wear and friction very high wear resistance and warm hardness good corrosion resistance, for low abrasion attack hard and good wear resistant coatings against finegrained abrasion attack, moderate corrosion resistance very good corrosion and cavitation resistant hard and corrosion resistant coatings hard and wear resistant coatings very low thermal expansion coefficient oxidation resistance at temperatures up to 900 C, high corrosion resistance high abrasion resistance when low corrosion attack compact wear resistant alloy good erosion resistance decoration

14 wear plate production of wear plates formed wear plate plasma arc cutting unit PA7 transverse section of typical FeCCralloy Production of wear plates Available dimensions of standard wear plates Standard choice for hardfacing alloys Size Dimension Coated area PTApowder Thaloy WSCDUR 60/40 (NiBSialloy 60 WSC) Small 000 x 000 mm 900 x 900 mm fluxcored Corthal FeCCrBalloy Medium 00 x 0 mm 0 x 00 mm wires Corthal 4 FeCCrNbBalloy Large 000 x 00 mm 80 x 0 mm Corthal 60 FeCCrNballoy Super 000 x 000 mm 80 x 80 mm Corthal 6 FeCCrNbBalloy Corthal 6 FeCCrNbMoVWalloy Thickness of plates openarcsurfacing with fluxcored wire electrode: mm, 4 mm, mm, 64 mm, 6 mm, 84 mm, 844 mm, 8 mm, 8 mm, 0 mm Standard choice for base materials SJRG, SJG, 6 Mo/Mo, CrMo4, CrMo44 We deliver our wear plates in standard size or cut according to your drawing also with bendings and fixing elements.

15 idling roller machining of hardfaced surface piercer for warm perforation CNCmachining of hardfaced idling roller submergedarc hardfacing of continuous casting roll Steel industry Special development Corthal 6 NOA for surfacing of continuous casting rolls in openarc process Corthal 498 for corrosion resistant, high temperature resistant and abrasion resistant surfacings at metallic sliding surfaces Thaloy 06 for hardfacing of piercers for warm perforation Thaloy 06 for hardfacing of teeths at warm saw blades 4

16 drop table coke chute lining for rotating chute sinter screen blast furnace chute Iron industry Special developments for the extreme application Corthal 800 in the hot sinter area Corthal F0 at coke chutes Corthal 4T at waste gas exhauster

17 lining for skip waste gas exhauster sinter crusher sinter grill bar lining for driving chute 6

18 screen covering handingover chute dish cutter wheel for excavator chassis excavator scoop Mining Special developments Corthal WSCDUR Fe(M) for hardfacing of dredger teeths and bucket lips special alloys for PTAwelding 7

19 dredger teeths lining for central funnel crawler chain part crawler chain part 8

20 fan cement roller press conveyor screw for cement clinker cement roller press Cement industry Special developments Corthal 4 for high strong buffer layers Corthal 600 TiC St and Corthal 760 for the extreme wear protection at cement roller presses Corthal 46 and Corthal 66 for crack free repairs at hardfaced cement roller presses Corthal WSCDUR(M) for long time wear protection at conveyor screws 9 9

21 segments of grinding dish impact drum air ring for coal mill radial cells dust distributor slag scratcher grinding roller Power plants Special developments Corthal F 740 for hardfacing of coal mills 0

22 reduction piece funnel inside hardfaced trouser part Inside hardfaced connecting pipe trough plates shredder rotor Inside hardfaced pipes and wear plate constructions Our offer Inside hardfacing by PTAwelding with carbide reinforced nickelbase alloys in diameter range 8070 mm Inside hardfacing of pipes with fluxcored wires in diameter range mm Wear plate bendings to pipes bigger than diameter 00 mm Constructions of inside hardfaced pipe bows and trouser parts wear plate constructions according to your drawings

23 mobile sparc spectral analyser mobile ultrasonic inspection technique high speed camera Ispeed scanning electron microscop REM/EDX reflected light microscope Neophot Xray flourescence analyser MIDEX NO and CSanalyser spark spectro analyser Foundry Master hardness testing machine mobile hardness testing technique Quality assurance, research and development Laboratory and development department We guarantee a constant high product quality by a continuous supervision of needed raw materials and finished products in our own laboratory. The solution of application specific wear problems by development of new materials and their process adaption is a permanent challenge for our research and development department.

24 Hamburg Bremen Hannover Berlin Magdeburg Duisburg Düsseldorf Köln Göttingen Thale Leipzig Dresden Frankfurt am Main Stuttgart München Powder Metallurgical CompetenceCentre worldwide active for you Corodur VerschleissSchutz GmbH Wolfsburgstraße a 060 Thale/Harz Telefon: 49 (0) Telefax: 49 (0) info@verschleissschutzthale.de