CCO

REXLINE™ CCO WEAR LINERS

As a genuine mining and quarrying wear liner suppoit service, REXLINETM have excellent quality REXLINETM CCO plate and weld wires. The microstructure of Cr7C3 carbide volume fraction is 50% or more which makes it one of the reliable REXLINETM CCO Liners on the market. The REXLINETM CCO range also comes in Niobium enrich. composition to provide additional abrasion resistance

The REXLINE” CCO plates can be:

• Counter Sunk

• Counter Bored

• Manufactured to complex profiles

• Fabricate and Roll Pip.

• Wear Bands

PERFORMANCE COMPARISON BETWEEN ULTRACAD AND OTHER WEAR PLATE

REXLINE supplies a wide range of chromium carbide and complex carbide overlay plates. Typical standard formats and Custom formats are supplied. Overlay thicknesses vary from 3mm to 30mm depending on the thickness of the base metal. Plates can also be cut to size, shaped and rolled according to customer specifications.
Item Hardness  (HRC) Max service  temperature Abrasion Impact Processability Service life
Steel Plate 35-55 Low * * ** *
Hardox 37-57 600 ** ** *** **
NM 33-42 600 ** ** *** **
Standard  Overlay Plates 58-62 600 ** *** ** ***
REXLINE™ UltraClad  Plates 65-67 600 *** *** ** ****

REXLINE™ CCO PLATE VS OPEN ARC WELDING

• Our REXLINE™ CCO’s are manufactured using the Submerged Arc welding process which is a much more controlled process.
• The difference between submerged arc welding and regular arc welding is that the welding wire,arc,and weld joint are covered by a layer of flux.
• The liners produced using the Sub Arc process has higher wear resistant properties compared to the Open Arc Welding Process.

REXLINE™ CCO ADVANTAGES:

• One of the top advantages of submerged arc welding is that it prevents hot materials from splattering and splashing onto workers.
• Another benefit is that the flux prevents high levels of radiation from being emitted into the air.
• This application is excellent for quickly welding together metal sheets and creates a secure fusion between welds.
• This application also produces high productivity, fast travel speed, high repeatability, and quality results.

REXLINE™ CCO WEAR LINERS

Submerged Arc Welding  UltraClad Plate

Open Arc Welding Overlay  Plate

Smooth Finish UltraClad  Plate

Countersunk holes

REXLINE™ CCO BUCKET LINERS

The REXI,IN, Bucket loader wear plates (REXI.IN, CCO) will outlast quenched and tempered steels by up to 12 times and white iron by up to 4 times.

The wear plates maintains the efficiency of chutes, bins, hoppers, buckets and other material handling equipment because it is quickly polished by abrading materials.

REXLINE”’ CCO TRUCK BED LINERS

REXLINE ™ CCO WEAR LINERS

REXLINE™ CCO Hardness Carbon(C) Silicon(S) Manganese(Mn) Phosphorus(P) Sulfur(S) Chromium(Cr) Molybdenum (Mo) Nickel(Ni) Copper(Cu) Boron(B) Tungsten(W) Ferrous Mb+Nb+Ti+V+W Mb+Nb+Ti+V
Ultraclad 60   >640 3.6-4.7% <1.87 1.1 – 2.9% <0.032 <0.021 22-34%  <0.03  <1.1 <0.06 <0.02
Ultraclad 80  >640 Arrive and Unpack  <1.87 1.1 -2.9% <0.032 <0.021 22-34%  <1.1 <0.06 <0.02 2.5 – 13%
Ultraclad PRO6000 >710 Arrive and Unpack <0.8 1.1 -1.5% <0.032 <0.021 24-34% 0.1-1.1% <0.02 2 – 6%  <0.1%

REX -700B CCO PLATE

PRO 6000 Earth Moving Equipment

UltraClad PRO6000 is perfectly suitable for hard facing  applications  which requires  impact resistance,  high abrasion  resistance and ability to withstand higher temperatures. The  temperature rating is up to 750°C. UltraClad range includes  HTCC which is manufactured with a mix of Tungsten  Chromium Carbides and Boron Carbides in a Nickel and  Silicon matrix.

The REXLINE™ Bucket loader wear plates (CCO) will outlast  quenched and tempered steels by up to 12 times and white  iron by up to 4 times.The wear plates maintains the efficiency  of chutes, bins, hoppers, buckets and other material handling  equipment because it is quickly polished by abrading  materials.

ULTRACLAD – CHROME CARBIDE LINERS

CCO FOR BATCHING PLAN

More Carbides = Higher Lifetime

The unique Carb-o-inject™ process ensures low dilution as well  as extra low penetration of temperature and high alloyed powder

Structure of a Rexcarb composite wearplate  with one layer of hardfacing by means of the  proprietary Carb-O-inject™ process.

The structure of the hard facing layer shows a  high content of primary chromium carbides  already close to the base layer.

Wearplate Fixing Techniques & Overlay Bead Orientation Options

Design your weld overlay beads for highest  wear performance.

Rexcarb composite wearplates are produced on CNC machines with  parametic bead orientation capabilities. Various bead orientation  options allow for designing the wear parts to have least wear-prone  zones. For example, in applications involving fine-dust erosion, it is  important that the stress relief cracks do not occur in the direction of  flow as it cloud  lead to preferential wear attack inside the cracks.

Zig-zag beads

Liner / angular  beads

Circular beads

Spiral stringer  beads

Welding of a nut with internal  thread into base material

Counter-sunk (CSK) holes by  electroerosion

Welding-on of stud

Weldable inserts

Fillet welding to base material

Plug welding to base  material

Common Mode of Industrial Wear

Metal Metal Friction

Wear caused by relative motion, direct contact and  plastic deformation which create wear debris and  material transfer from one metal surface to another

Mineral Abrasion

Wear caused when mineral particles of  suitable, hardness, shape and texture slide  across a metal surface leading to loss of  material. It can be 2-body or 3 body type.

Abrasion Under Pressure

Wear caused when mineral particles of suitable  hardness, shape and texture slide across a metal  surface under high pressure leading to loss of  material and superficial deformation

Hot Abrasion

Mineral abrasion in a high-temperature  environment, leading generally to softening  of the metal or its constituents.

Mechanical fatigue

Wear Resulting from subsurface cracking and  fracture induce by tribological stress cycles.

Cavitation

Tearing out of grains from the metal  surface by the formation and implosion of  bubbles in a liquid in rapid motion

Impact

Wear due to collisions between two solid  bodies where some component of the motion is  perpendicular to the tangential plane of  contact. This phenomenon is controlled by the  toughness or ductility of the two materials.

Hot oxidation

Wear caused due to cyclic formation and removal of  the oxide layer (formed due chemical reaction  between metal surface and oxygen at high temperatures). Degradation is caused due loss of thickness.

Erosion

Wear caused by repentitive high-speed impact  of mineral particles against the surface of an  object. The impacting particles gradually  remove material from the surface through  repeated deformations and cutting action

Thermal fatigue

Wear caused by progressive degradation of a  material due to cyclic fluctuations in temperature  leading to alternate expansion and contraction.

Corrosion

Wear  in  which  chemical  or  electrochemical reaction  with the environments is significant

Project Overview

Manufacturer – REXLINE— Engineering

Product – Chromium Carbide Overlay Wear Bands

Purchase Order – 166581

Date of Purchase – February, 28 2018

Case Study

  • The client, was in dire need for high wear resistant material for the sizing crusher. The drum inside  the crusher wears out quickly hence resulting in breakdowns and high maintenance intervals.  Considering these equipment’s re highly performance driven and tonnage achieved is of  importance, a breakdown is last thing needed.
  • REXLINE™ has developed its Chromium Carbide Steel Liner over years of reengineering and tests  conducted over its chemical composition based on client requirements. REXLINE™ engineers  suggested this product based on similiar past applications.
  • Considering the Shape and manufacturability, these liners were welded on submerged arc welding  station and were curved to suit the drum profile. As part of its services, REXLINE™ conducterd  QA/QC and Dimensional Checks to ensure the product is top quality and can be installed on the  crusher with ease and each liner can be intrcharged.

Technical Specification

Technical Data Chemical Composition of Wear Resistant Material Deposition

Size 12 On 12 Grade  DUO   Standard AS/NZS2576:2005
Description C Cr Mn Si Fe
Requirement 3.00 – 5.00 34.0-45.0 0.5-2.50 0.50-1.50
 Test Result  4.12  39.4 1.02  0.81 Bal
 Hardness of Deposited Metal 58 – 63
Recorded Hardness 62.2

Project Benefit Review

Parameter Benefits
Service Life The steel liners were installed in March 2018 in the crusher. It was replaced in November 2018.

Service Life : 8 Months.

The service life Increased by 25%

Cost Replacement and Maintenance costs of these belts was reduced by 35% Considering for a year’s worth of service life

Visual Checks

Hardness Checks

Figure 1 : Section Hardness of Backing Plate

Figure 3 : Surface Hardness

Figure 2 : Section Hardness of Wear Resistant Layer

Dimensional Checks

Figure 4: Arc Length

Fig5: Width of the liner

Figure 6 : Chord Length

Figure 7 : Square Check