Using hardfacing technology to protect hardware | Engineer Live

Sustainability and environmental responsibility are increasingly important in the race to combat climate change. The recycling industry stands at the forefront of this movement, playing a crucial role in reducing waste and conserving valuable resources. With facilities processing ever-increasing volumes of diverse materials, equipment is subjected to extreme wear and tear. Cutting and shredding components - such as sickle blades, hammer teeth, conveyor screws, and crusher jaws - face constant abrasion, impact, and material fatigue.

One highly effective solution is the use of advanced hardfacing technology to protect these critical components, improving their wear resistance and extending their service life. Producer of advanced welding consumables Welding Alloys is at the forefront of this approach, providing tailored hardfacing solutions to recycling plants worldwide.

A recent case study illustrates the significant benefits of hardfacing. Greenworld, a Kings Lynn based recycling and waste management company, approached Welding Alloys in a bid to address a recurring issue: the sickle blades in its twin-shaft shredder required replacement after approximately 500 hours of operation; owing to wear from the material being processed, including tramp material such as metal and hardcore. The shredder contained 167 sickle blades, and each replacement cycle involved two full days of downtime - a major disruption to production schedules. While the customer had consulted the OEM, there were no substantial improvements in blade longevity at that time. Faced with rising costs and downtime, they needed a more sustainable, long-term solution.

Welding Alloys proposed a trial using their advanced Hardface range of welding consumables. By hardfacing the blades with different consumables, specifically from the WA Integra series, they aimed to improve wear resistance and extend service life. The trial included hardfacing several worn blades and putting them back into service. After the trial, the customer installed the modified blades into operation and began closely monitoring performance.

The results were promising. Once the trial period ended, the customer removed and compared the trial blades with standard OEM versions. After 242 hours of service it was clear that the standard OEM versions had been outperformed by one of the Welding Alloys’ blades. It not only showed significantly better wear resistance but retained the original shape of the knives - particularly the tips.

Maintaining the tip of the blade is critical. Without it, material often remains unprocessed after a single cycle, forcing the machine to perform a second pass. By preserving blade geometry and sharpness, the hardfaced solution improved cutting performance, reduced the need for preprocessing, and directly contributed to increased throughput.

This success underscores Welding Alloys’ commitment to innovation and their ability to deliver customised solutions to meet the unique needs of recycling operations.

David Kilham, new sector development, Greenworld said: “We’ve seen significant results since working with Welding Alloys. The hardfaced blades outlasted our standard OEM blades by a significant amount, and that will have a direct impact on our operational efficiency. What used to be a 500-hour replacement cycle is now significantly extended, and this will reduce our downtime and maintenance costs considerably. On top of that, the cutting performance is noticeably sharper for longer, helping us improve throughput and reduce double-processing. The Welding Alloys team took the time to understand our challenges and delivered a tailored solution that truly works – it’s been a game changer for us.”

1. Reduced downtime: By extending the wear life of critical components, Welding Alloys’ solutions minimise the need for frequent replacements, reducing downtime and enhancing operational efficiency.

2. Cost savings: The extended service life of equipment translates to cost savings, as the need for frequent replacements and maintenance is reduced.

3. Tailored solutions: Welding Alloys works closely with customers to trial and identify the optimal hardfacing consumable for each application, ensuring maximum effectiveness.

4. Improved wear resistance: The hardfacing process significantly improves the wear resistance of equipment, ensuring that it can withstand the rigorous conditions of recycling processes.

5. Increased productivity: With more durable equipment, recycling facilities can operate more consistently, leading to increased productivity and output.

6. Sustainability: Prolonging component life reduces material waste and energy consumption associated with manufacturing and shipping replacements.

The recycling industry is at the forefront of the global effort to create a more sustainable future. Innovations like those offered by Welding Alloys are crucial in enhancing the efficiency and effectiveness of recycling operations. By addressing the challenges of wear and tear, and providing customised, field-tested solutions, Welding Alloys is setting a new standard for recycling equipment. As the industry continues to evolve, such innovative solutions will be instrumental in achieving greater sustainability and resource conservation.

Investing in advanced recycling technologies is not just a business decision - it is a commitment to a greener future. Solutions such as those from Welding Alloys help recycling facilities operate more efficiently, contributing to a cleaner environment and a more sustainable world.

For more information visit: www.welding-alloys.com