Impact Wear (Impact + Abrasion)
In crushers, shredders and mills the part is both abraded and impacted. Under these conditions a very hard but brittle coating cracks quickly; the right solution balances toughness and hardness.
Symptoms
- Chipped, mushroomed edges and burrs
- Transverse cracks and spalling in the hardfacing
- Rapidly shortening hammers, blades and teeth
- Balance and vibration problems from weight loss
Typical Parts
Impact energy cracks hard, brittle phases; particles entering the cracks accelerate abrasion. If the transition between base material and hardfacing is not built correctly, the overlay can come off in one piece.
Which Process for Which Case?
As impact increases, high-toughness alloys and a buffer layer become more important.
| Solution | Material System | Typical Thickness | When Is It the Right Choice? |
|---|---|---|---|
| Buffer layer + hardfacing | Tough buffer + chromium / complex carbide | 3–10 mm | Medium–high impact; hammers, liners, crusher parts |
| PTA hardfacing | NiCrBSi + WC | 1.5–4 mm | Low–medium impact and high abrasion; blade edges, mixer arms |
| Weld restoration | Filler matched to base material | By loss | Bringing a shortened part back to its geometry |
| HVOF | — | — | Not recommended for high impact; thin carbide coatings crack under impact |
Values are typical ranges; the final choice is made after the part, base material and operating conditions have been seen.
The right alloy only works with the right welding procedure
On manganese steel and high-carbon parts, wrong preheat, interpass temperature or buffer layer choice leads to cracks under the overlay. If you do not know the base material, we start with spark and hardness testing.
FAQ
How many times can crusher hammers be rebuilt?
More than once if the base material and section allow. Before each rebuild a crack check is made; weight and balance are kept in line.
Which hardfacing is best for shredder blades?
With low impact, tungsten carbide overlay by PTA; with high impact, chromium carbide with a buffer layer usually gives longer life.
Do you do hardfacing on site?
Where suitable, our field team performs on-site weld repair and hardfacing.
Let’s Talk About Your Part
Take a photo of the damaged area and send it by e-mail or WhatsApp, or call us directly. On the phone we identify the mechanism together and give a suitable process and a rough cost/lead-time indication in the same call.
- Close-up and overall photo of the damaged area
- Diameter / length or a technical drawing
- Operating conditions: temperature, medium, particles, speed