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Welcome to VEGA Industries LTD. Sintercast vs Hardfacing Comparison

Sintercast vs Hardfacing.pdf

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Page 1: Sintercast vs Hardfacing.pdf

We

lco

me

to

VEG

AIn

du

strie

s LT

D.

Sin

terc

ast

vs

Ha

rdfa

cin

gC

om

pa

riso

n

Page 2: Sintercast vs Hardfacing.pdf

HA

RD

FA

CIN

G

Page 3: Sintercast vs Hardfacing.pdf

IN S

ITU

IN T

HE W

OR

KSH

OP

WA

YS O

F H

AR

D F

AC

ING

Page 4: Sintercast vs Hardfacing.pdf

�It

ha

s sh

ort

de

live

ry t

ime

as

co

mp

are

d to

ne

w s

et

.

�P

oss

ibili

ty o

f re

-use

of

ba

se m

ate

ria

l m

ore

nu

mb

er

of tim

es.

�In

situ

ha

rd fa

cin

g h

elp

s in

ke

ep

ing

ori

gin

al p

rofile

.

�A

va

ilab

ility

of

ma

ny

su

pp

liers

an

d v

ari

ety

of

ele

ctr

od

es

in t

he

ma

rke

t.

�N

o s

pe

cific

te

ch

niq

ue

is

req

uir

ed

. C

he

ap

la

bo

r a

va

ilab

le in

th

e m

ark

et.

WH

AT

CU

STO

ME

R B

EL

IEV

ES

A

BO

UT

HA

RD

FA

CIN

G

Page 5: Sintercast vs Hardfacing.pdf

�V

ery

hig

hrisk

of

ca

stin

gb

rea

ka

ge

du

rin

go

pe

ratio

n.

�Li

mite

dLa

ye

ro

fh

ard

fac

ing

du

eto

safe

tyre

aso

n.

�M

ultip

letim

eh

ard

fac

ing

resu

lts

inc

rac

kin

go

fc

ast

ing

.

�D

iffic

ult

tom

ain

tain

sam

ep

erf

orm

an

ce

eve

nw

ith

ide

ntic

al

laye

ro

fh

ard

fac

ing

.

�U

na

ble

tom

ain

tain

the

sam

ep

rofile

du

eto

exp

an

sio

na

nd

shrin

ka

ge

.

�Fu

me

sg

en

era

ted

urin

gh

ard

fac

ing

ish

ea

lth

ha

zard

ou

sfo

rh

um

an

be

ing

.

�G

en

era

tio

no

fsu

rfa

ce

cra

ck

isin

evita

ble

an

da

lwa

ys

risk

of

failu

re.

�In

ca

seo

fin

situ

ha

rdfa

cin

g,

do

wn

tim

ein

cre

ase

sa

nd

red

uc

es

mill

ava

ilab

ility

�D

ire

ct

Loss

of

pro

du

ctio

na

nd

reve

nu

eg

en

era

tio

nd

urin

gst

op

pa

ge

for

in

situ

ha

rdfa

cin

g.

�H

ard

fac

ing

at

insi

tuc

on

ditio

nm

ay

ca

use

be

arin

gfa

ilure

s.

WH

AT

IS T

HE R

ISK

IN

HA

RD

FA

CIN

G

Page 6: Sintercast vs Hardfacing.pdf

Sh

ap

ing

a w

orl

d o

f P

erf

orm

an

ce

领先一步

领先一步

领先一步

领先一步

, 追求

追求追求

追求卓越

卓越卓越

卓越

INIT

IALL

Y S

TAR

T W

ITH

SM

ALL

ER

C

RA

CK

AN

D T

RA

NSFO

RM

IN

TO P

IEC

ES

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

Page 7: Sintercast vs Hardfacing.pdf

Sh

ap

ing

a w

orl

d o

f P

erf

orm

an

ce

领先一步

领先一步

领先一步

领先一步

, 追求

追求追求

追求卓越

卓越卓越

卓越

RO

UG

H S

UR

FAC

E

Page 8: Sintercast vs Hardfacing.pdf

VIZA

G S

LAG

LM

46.

2+2

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

Page 9: Sintercast vs Hardfacing.pdf

ULT

RAT

ECH

–TA

DIP

ATR

I

LM

53.

3+3

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

Page 10: Sintercast vs Hardfacing.pdf

ULT

RAT

ECH

–G

INIG

ERA

L

M

53.3

+3

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

Page 11: Sintercast vs Hardfacing.pdf

DAL

MIA

L

M 4

6.2+

2

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

Page 12: Sintercast vs Hardfacing.pdf

OR

IGIN

AL M

ATER

IAL

HI-C

HR

OM

E. W

ELD

ING

AFT

ER 8

00

HR

S. B

REA

KAG

E IN

FEW

DAY

S AF

TER

HAR

D F

ACIN

G

CR

AC

K O

N H

AR

D F

AC

ED

LA

YER

ACC

BAR

GAR

H -

MPS

560

0 BC

Page 13: Sintercast vs Hardfacing.pdf

Sh

ap

ing

a w

orl

d o

f P

erf

orm

an

ce

领先一步

领先一步

领先一步

领先一步

, 追求

追求追求

追求卓越

卓越卓越

卓越

SP

ALL

ING

ON

HA

RD

FA

CED

LA

YER

Page 14: Sintercast vs Hardfacing.pdf

�R

ed

uc

es

the

ma

inte

na

nc

ec

ost

�N

orisk

of

ca

stin

gb

rea

ka

ge

du

rin

go

pe

ratio

n.

�O

rig

ina

lp

rofile

ca

nb

em

ain

tain

ed

for

mu

ch

lon

ge

rtim

ea

nd

du

eto

wh

ich

pe

rfo

rma

nc

ew

illb

ec

on

sist

en

t.

�Sin

ter

laye

rw

illb

em

ore

ha

rde

rth

an

ha

rdfa

cin

gla

ye

ra

nd

cre

ate

un

ifo

rm

we

ar

on

the

ca

stin

g.It

red

uc

es

the

po

we

rc

on

sum

ptio

n.

�R

ed

uc

eth

est

op

pa

ge

for

insi

tuh

ard

fac

ing

an

dm

inim

ize

the

risk

of

pro

du

ctio

nlo

ssa

nd

dire

ct

reve

nu

eg

en

era

tio

n.

�M

uc

hle

sse

rw

ea

rra

tea

sc

om

pa

red

toh

ard

fac

ing

an

dg

ive

sm

uc

h

hig

he

rw

ea

rlif

e.

�R

ed

uc

es

the

ma

inte

na

nc

ea

nd

op

era

tin

gc

ost

.

�M

ills

ca

no

pe

rate

at

hig

he

ro

pe

ratin

gp

ress

ure

an

dim

pro

ve

sth

e

op

era

tin

ga

nd

pe

rfo

rma

nc

ep

ara

me

ters

.

�W

eh

ave

ob

serv

ed

tha

tso

me

of

the

cu

sto

me

ris

ha

rdfa

cin

go

nth

ero

ller

tire

aft

er

we

ar

of

ha

rde

ne

dsi

nte

rla

ye

r.W

ea

ren

ot

ina

favo

ro

fh

ard

fac

ing

on

the

we

ar

resi

sta

nt

ca

stin

g.

AD

VA

NTA

GES O

F SIN

TER

CA

ST

OV

ER

H

AR

D F

AC

ING

Page 15: Sintercast vs Hardfacing.pdf

AIA

E /

Ve

ga

alw

ays

striv

e t

o a

ch

iev

e t

ota

l cu

sto

me

r sa

tisf

ac

tio

n:

-B

y p

rovid

ing

be

tte

r so

lutio

ns

in a

bra

sio

n r

esi

sta

nc

e p

rod

uc

ts.

-Th

ese

so

lutio

ns

he

lp c

ust

om

ers

re

du

ce

th

eir t

ota

l c

ost

of

pro

du

ctio

n.

WH

Y S

INTE

R C

AST

?

Page 16: Sintercast vs Hardfacing.pdf

Imp

rove

d w

ea

r lif

e

Life

tim

e is

inc

rea

sed

by 1

.5 –

2.5

tim

es

de

pe

nd

ing

on

th

e c

ha

rac

terist

ics

of

the

ra

w m

ate

ria

l gro

un

d.

Tota

l sa

fety

ag

ain

st b

rea

ka

ge

The

ha

rd in

sert

s a

re e

mb

ed

de

d in

th

e c

ore

of

no

du

lar

iro

n. Th

e n

od

ula

r iro

n is

h

igh

ly d

uc

tile

an

d c

ap

ab

le o

f w

ith

sta

nd

ing

se

ve

re s

ho

cks.

The

inse

rts

are

me

ch

an

ica

lly b

on

de

d t

o t

he

ba

se m

eta

l. Th

ere

is n

o

me

tallu

rgic

al b

on

d,

he

nc

e e

ve

n if

sma

ll c

rac

ks

ap

pe

ar

in t

he

in

sert

s, t

he

se

ca

n n

ot

pe

ne

tra

te t

hro

ug

h t

he

du

ctile

co

re

AD

VA

NTA

GES O

F SIN

TER

CA

ST

Page 17: Sintercast vs Hardfacing.pdf

Co

nsi

ste

nc

y o

f M

ill p

erf

orm

an

ce

:

Tailo

r m

ad

e s

olu

tio

n p

rovid

es

un

ifo

rm w

ea

r p

rofile

.

Un

ifo

rm w

ea

r p

rofile

re

sults

in c

on

sist

en

tly m

ain

tain

ing

mill

op

era

tin

g

pa

ram

ete

rs.

The

co

nst

ruc

tio

n r

esu

lts

in b

itin

g a

ctio

n o

n t

he

ra

w m

ate

ria

l th

ere

by

red

uc

ing

th

e s

lipp

ag

e.

Re

du

ce

d s

lipp

ag

e r

esu

lts

in b

ett

er

grin

din

g e

ffic

ien

cy.

Re

du

ctio

n in

Mill

do

wn

tim

e:

Hig

he

r lif

etim

e r

ed

uc

es

the

no

. o

f st

op

pa

ge

s.

Mill

ava

ilab

ility

inc

rea

ses

du

e t

o le

ss a

dju

stm

en

ts.

Re

pla

ce

me

nt

ca

n b

e p

lan

ne

d t

o m

atc

h t

he

an

nu

al s

hu

tdo

wn

s.

AD

VA

NTA

GES O

F SIN

TER

CA

ST

Page 18: Sintercast vs Hardfacing.pdf

CO

ST

CO

MPA

RIS

ON

Ma

dra

s C

em

en

t-(A

lath

iyu

r),

LM56.2

0+

2

Page 19: Sintercast vs Hardfacing.pdf

CO

ST

CO

MP

AR

ISO

NB

ASED

ON

AC

TUA

LD

ATA

,M

AY

NO

TB

ESA

ME

FOR

OTH

ER

PR

OJE

CTS

.W

ESU

GG

EST

NO

TTO

CO

NSID

ER

THIS

PER

OFM

AN

CE

AN

DPR

AC

TIC

EO

FH

AR

DFA

CIN

GA

SA

SO

LUTI

ON

.

Ma

dra

s C

em

en

t-(A

lath

iyu

r),

LM56.2

0+

2

Co

ntd

--

Page 20: Sintercast vs Hardfacing.pdf

CO

ST

CO

MP

AR

ISO

N

Co

st C

om

pa

riso

n o

f H

ard

Fa

cin

g r

olle

r w

ith

Sin

ter

Ca

st

Mill

Ty

pe

Ce

me

nt

Mill

Pla

nt

MC

L Ja

ya

ntip

ura

m

We

igh

t o

f e

ac

h R

olle

r Ti

re8

40

0 K

gN

o O

f R

olle

r2

Ca

lcu

latio

n

Typ

eC

ost

USD

Ru

nn

ing

h

ou

rsR

em

ark

s

Co

nv

en

tio

na

l7

22

40

10

00

0C

ost

for

two

rolle

rtire

.M

ult

iple

ha

rdfa

cin

gu

pto

10

00

0h

rso

pe

ratio

n.

No

Of

tim

es

Ha

rdFa

cin

g1

4A

fte

rEve

ry7

00

Hrs

Op

era

tio

n.

No

rma

llyp

oss

ible

ha

rdfa

cin

gin

be

twe

en

14

tim

es

on

ea

ch

rolle

rtire

Co

sto

fw

eld

ing

pe

rK

g1

0.8

Tota

l3

00

kg

ele

ctr

od

es

co

nsu

mp

tio

no

ntw

oro

llertire

pe

r7

00

hrs

op

era

tio

n

Ma

xim

um

We

ar

at

the

tim

eo

fh

ard

fac

ing

14

-20

mm

70

0H

rs2

0-3

0m

mp

er

10

00

hrs

op

era

tio

n

Tota

lC

ost

of

Ha

rdFa

cin

gA

fte

re

ve

ry7

00

hrs

op

era

tio

n3

24

07

00

Hrs

Aft

er

Ev

ery

70

0H

rsO

pe

ratio

n

Tota

lCo

sto

fH

ard

Fac

ing

46

28

61

00

00

Tota

lC

ost

of

ori

gin

alse

tp

lus

ha

rdfa

cin

g/

Ho

ur

for

ori

gin

alse

t1

18

52

5.7

10

00

0

Co

st/

Ho

ur

for

Ha

rdFa

cin

g4

.6U

SD

/h

r.

Co

stP

er

ho

ur

inc

lud

ing

Ori

gin

al

set

with

Ha

rdFa

cin

g1

1.9

USD

/h

r.In

clu

din

gH

ard

Fa

cin

gu

pto

10

000

Hrs

op

era

tio

n

Page 21: Sintercast vs Hardfacing.pdf

Co

st C

om

pa

riso

n o

f H

ard

Fa

cin

g r

olle

r w

ith

Sin

ter

Ca

st

Mill

Ty

pe

Ce

me

nt

Mill

Pla

nt

MC

L Ja

ya

ntip

ura

m

We

igh

t o

f e

ac

h R

olle

r Ti

re8

40

0 K

gN

o O

f R

olle

r2

Allo

yN

i H

ard

IV

w

ith

H

ard

Fa

cin

gSin

ter

ca

stU

nits

Ma

xim

um

we

ar

40

40

mm

Ru

nh

rs1

00

00

Life

ac

hie

ve

d W

ith

ou

t H

ard

Fa

cin

g

IN 7

00

0 H

RS

an

d s

till

in o

pe

ratio

n

We

ar

Sp

ee

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0.0

4.2

9In

ca

se o

f Sin

ter

ca

st m

ax

we

ar

of

30

mm

wa

s o

bse

rve

d a

fte

r 5

40

0 h

rs

op

era

tio

n

Co

sto

fse

t8

73

60

USD

Co

st/

hrs

8.7

USD

/ h

r.

Eq

uiv

ale

nt

Co

stfo

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00

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Hrs

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vin

gin

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ter

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10

15592.0

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tra

Re

ve

nu

ep

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hrs

du

eto

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ter

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st1

101.6

USD

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Ind

ire

ct

ad

va

nta

ge

s

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Co

nsi

ste

nc

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mill

ou

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ed

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