1.1 Definition of Cladding
Cladding is a surface modification technology mainly used to form a layer of cladding with specific properties on the surface of the substrate to improve the wear resistance, corrosion resistance, high temperature performance of the substrate. The process of cladding is generally metal powder or alloy powder and other materials through the laser, arc, plasma and other ways to heat to a molten state, and fused with the surface of the substrate to form a solid coating. There is usually a certain metallurgical bond between the fusion cladding layer and the base material, which ensures high adhesion of the coating.
Application areas of cladding
Cladding technology is widely used in
• Petrochemicals
• Aerospace
• Automotive
• Mold
• Metallurgy
Metallurgy and many other fields.
Cladding technology is used to repair and improve mechanical components. The main objective is to extend the service life of the parts, reduce wear and corrosion damage and to be able to modify the surface in a short time.
Types of cladding
Utilizing high-energy laser beam to heat the cladding material, characterized by high precision and small heat-affected zone.
Utilizing plasma arc heating, suitable for handling thicker cladding and large workpieces.
3. Electric arc cladding
Heated by electric arc, lower cost, commonly used in large structural parts of the surface strengthening.
4. Flame spraying cladding
Utilizing flame to spray the coating material onto the surface of the substrate, mainly used for low and medium strength protective cladding.
The main advantages of cladding technology
1. Improvement of material properties: it is possible to obtain the desired properties (e.g. abrasion and corrosion resistance) on the surface of the substrate.
2. Reduced material consumption: only the surface needs to be clad, reducing the use of expensive materials.
3. Extended equipment life: Significantly improves the service life of equipment parts and reduces the frequency of maintenance.
4. Environmentally friendly and economical: reduces the need for traditional replacement parts, saving costs and resources.
Steps of cladding
• Material Preparation: Selection of suitable cladding material, such as metal powder, alloy powder or ceramic.
• Heating and Fusing: Heat the cladding material to a molten state using a heat source.
• Coating and fusion: Formation of a metallurgically bonded coating on the surface of the fused material and the substrate.
• Cooling and solidification: After cooling, the cladding material solidifies on the surface of the substrate to form a coating with specific properties.
Cladding is a highly efficient and cost-effective surface enhancement process, which can realize the functional enhancement of the surface while guaranteeing the properties of the substrate itself. Different cladding technologies, such as laser cladding, plasma cladding, arc cladding, etc., have their own applicable scenarios and characteristics, and the appropriate cladding method is usually selected according to the specific process requirements and material properties.
1.2 About wear solutions
Wear is the material loss of mechanical parts due to friction during long-term operation, which affects the performance and service life of the equipment. In order to solve the wear problem, different solutions need to be selected according to the specific situation.
What is a wear solution?
Wear solutions are terminologically designed to address and minimize the loss of material due to friction in a particular machine or piece of equipment.
Types and varieties of wear
Wear can be categorized in different ways depending on the situation. Understanding the many types of wear will help you to recognize what kind of wear your machine or equipment is experiencing in order to obtain a wear solution that is better suited to your needs!
1. Abrasive wear
Abrasive wear is the loss of material caused by the movement of hard particles (abrasive grains) between contacting surfaces or embedded in the surface. Abrasive particles can be foreign objects that enter from outside, or they can be debris produced by the material itself during the wear process.
- Characteristics: Formation of pits, scratches or plastic deformation on the surface of the material.
2. Adhesive wear
Adhesive wear refers to the microscopic welding and subsequent tearing of two materials in contact with each other during relative motion, resulting in material transfer or loss. Adhesive wear is often exacerbated by high temperatures or pressures on the contact surfaces.
- Characteristics: Microscopic weld and tear marks on the material surfaces, possible material transfer.
3. Fatigue wear
Fatigue wear is the result of stress concentrations caused by repeated stresses on the contact surfaces, which leads to micro-cracks in the surface material and ultimately to material spalling. Fatigue wear occurs mainly on parts subjected to cyclical loads.
- Characteristics: Small cracks or shedding particles on the surface, showing pitting or skin flaking.
4. Corrosive wear
Corrosive wear refers to the material in the friction process, due to chemical or electrochemical reaction caused by corrosion, coupled with friction aggravated corrosion product stripping, thereby accelerating material loss.
- Characteristics: the wear surface shows oxidation, rust or corrosion pits.
Different types of wear vary in mechanism, characteristics and countermeasures. Common solutions include selection of wear-resistant materials, surface treatment, lubrication, structural optimization and environmental control. Understanding the types and characteristics of wear can help you take more targeted protective measures to extend the life of your parts.
Application areas for wear solutions
• Manufacturing
• Mines and Mining
• Oil & Gas
• Power & Energy
• Automotive industry
• Construction and engineering machinery
• Aerospace
• Agricultural Machinery
• Marine Engineering
Cladding and wear solutions
Cladding, as a common surface engineering technique, plays an important role in wear solutions. By cladding wear-resistant materials onto the surface of a substrate, wear resistance, corrosion resistance and impact resistance can be significantly improved, thus extending the service life of the part.
The role of cladding in wear solutions
1. Enhanced wear resistance: Cladding materials typically have high hardness and wear resistance, which reduces wear in high wear environments.
2. Improved corrosion resistance: Some specific cladding materials are chemically resistant, making them suitable for use in corrosive environments such as wet, acidic, alkaline or marine environments.
3. Extend service life: By forming a high wear-resistant coating on the surface of the substrate, it effectively extends the service life of the equipment and parts, and reduces the frequency of maintenance and replacement.
4. Enhance impact resistance: some alloy cladding materials have good toughness, which can reduce the damage of impact on the surface of the parts, and are suitable for equipment that needs impact resistance.
Where can you get wear solutions?
There are many companies and organizations that offer wear and tear solution services. However, if you want to find the best service, do not hesitate to work with ShanghaiDuomu. We are the best in China and no other company can take away our laurels. Many companies consider us to be the most skilled wear solution company in China. To get the ideal wear solution, don't hesitate to contact us to get first-class service from the most professional engineers!
Post time: Nov-05-2024