ONE STOP WHOLE-OF-MINE MATERIALS HANDLING SERVICE WEARX FOUNDRY CAPABILITIES
FACILITY WEARX s foundry facility is based in Ballina in Northern New South Wales, Australia. The WEARX foundry provides a rapid response and short lead time service for cast liners and other cast products. The facility offers Australian Standard quality iron and steel castings in a vast array of alloy specifications from 1kg to 1 tonne. The foundry is managed by a stringent quality management system (QMS) accredited to the standard AS/NZS ISO 9001 and a management and support team with a combined 140 years of specialised experience. CAPABILITIES & FEATURES 1375m² undercover workshop Spectrometer analysis Non-Destructive Testing (ultrasonics) Micrographic examination, hardness and tensile testings Patternmaking
WEARX FOUNDRY SPECTROMETER ANALYSIS Our team of metallurgists test material using spectrometer analysis before each batch of castings is poured. Once the furnacemen melt down the specific amounts of material required for a pour, our metallurgists test a sample of each batch using a spectrometer. The spectrometer measures the material to ensure it contains the correct amount of each element and will deliver the correct level of hardness, ductility and various other properties. PATTERN MAKING WEARX has a seperate pattern making facility to ensure designs can be turned into castings. This enables us to construct wooden patterns which are then turned into moulds to create castings. MOULDING We have two separate moulding units that consist of the following: Looping for higher volume type work batches from 5 to over 100 Jobbing for larger one-off items Our team use a resin sand casting process or hard sand moulding system. After mixing and burning, the resin sand becomes hard and solid, forming a hard mould. The resin sand s solid structure ensures accurate dimensional accuracy and a smooth surface finish for every casting. MELTING The facility has two induction melting furnaces of 1 tonne and ½ tonne capacity which provide us the flexibility to perform small and large batches of castings. FETTLING Once castings are set, our experienced fettling team inspect and condition to ensure each casting is ready for installation.
MATERIALS WEARX manufacture castings from high chrome irons (in particular 27% chrome), spheroidal graphite (SG) cast iron and Ni-hard cast irons. Material samples are tested using spectrometer analysis at the facility s laboratory before castings are poured to ensure materials will perform to the standard at which the application requires. Our team of engineers and metallurgists work with the client to ensure the right material and design is chosen that will deliver maximum wear life and optimise the material handling process. PRODUCTS Our team produce castings for a variety of applications and industries. Our design and engineering team design custom cast solutions to meet specific operational needs. Products include: Wear liners Wear parts Pipes Blow bars Gear boxes
WEARX FOUNDRY OUR ADVANTAGE Unlike other operations our foundry facility has the capability to respond to rapid lead times and we constantly meet very demanding delivery times to meet operational needs. Our facility is quality accredited to the standard ISO 9001 which ensures all castings are manufactured to high quality standards. We have the ability to create new products and alloy combinations to meet customer specifications. This provides us with the flexibility to meet all operational environment needs. See below WEARX cast solutions used in different mining applications.
OFFICES HEAD OFFICE NEWCASTLE 230 Old Maitland Rd Hexham NSW 2322 P: +61 2 4962 3433 F: +61 2 4962 3722 PERTH Unit 3/32 Beach St Kwinana Beach 6167 P: +61 8 9439 2396 M: +61 429 301 510 ORANGE 1 Stephen Place Orange NSW 2800 P: +61 2 6360 1333 F: +61 2 6360 1344 BALLINA 40 Piper Drive Ballina NSW 2471 P: +61 2 6686 2577 F: +61 2 6686 2435 ROXBY DOWNS Lot 16 Charlton Rd Olympic Dam SA 5725 P: +61 418 974 066 MOUNT ISA Business Development Representative M: +61 437 890 944 www.wearx.com support@wearx.com 020316