Abrasion and Wear Resistance

Abrasion and Wear Resistant Coatings

Abrasion and corrosion are two of the biggest enemies of machinery and equipment. Abrasion can be caused by a number of factors, including friction, vibration, and impact.  Corrosion refers to the gradual loss of material from a surface due to exposure to a reactive environment like salt water, chlorine, or acids.  Together or separately, abrasion and corrosion can cause serious damage to machine components, leading to expensive repairs or even complete failure.  Hayden Corp. offers thermal spray coatings that are highly resistant to both abrasion and corrosion. These coatings can be applied to a wide range of surfaces, including metal, ceramic, and composites.

Achieving desired corrosion and abrasion performance with thermal spray requires an understanding of the interactions between the substrate material, the applied coating, and the environment. In general, harder coatings will exhibit better wear resistance than softer ones. However, this is not always the case, as coatings can be too hard and brittle to withstand the impact of abrasive particles. The operating environment also plays a role in corrosion and abrasion resistance, as coatings that are exposed to high temperatures or corrosive chemicals will break down more quickly. To achieve the best possible performance, Hayden Corp. will apply material that is compatible with both the substrate and the environment.

Common Wear and Abrasion Resistant Coating Applications

Abrasion and wear resistant coatings by Hayden Corp. are used in a wide variety of industries and applications. Some of the most common uses for these types of coatings include:

• Roll Surfaces
• Pump & Valve Components
• Plastic Molding and Compounding Machinery
• Pipelines & Conduits
• Conveyor System Components
• Cement Mill Equipment & Auger Screws
• Wind Turbine Components

Abrasion and Corrosion Resistant Materials

The thermal spray process allows for excellent control of surface characteristics by controlling hardness and chemistry at the point of contact.  As a result, this technique offers enhanced corrosion and abrasion resistance, even in difficult work environments such as those involving friction, abrasion, extreme temperatures, or corrosive chemicals.  Common materials used include:

Tungsten Carbide

Tungsten carbide is a very hard compound with superior wear resistance, ideal for long-wearing surfaces and edges. This tough and durable material has many applications in industry, as it can stand up to extreme wear and abrasion with minimal material loss. Its durability makes it an ideal choice for things like cutting tools, wear plates, roll and bearing surfaces, and parts of heavy machinery susceptible to abrasion. Carbide coating materials may also be ground and superfinished to provide an extremely hard mirror-like finish. Overall, tungsten carbide offers truly outstanding wear and abrasion resistance, making it an invaluable material for a wide range of industrial applications.

Chromium Carbide

Like tungsten carbide, chromium carbide provides excellent protection from sliding wear and abrasion. Although it is not as hard or durable as tungsten carbide, it is capable of withstanding higher operating temperatures than tungsten carbide, and is the preferred choice for wear applications in turbine hot sections. Chromium carbide can be applied by plasma or HVOF, and can also be ground to fine finishes. 

Aluminum Oxide

Aluminum Oxide is often used in high wear applications due to its excellent abrasion resistance. This very hard material can withstand extreme abrasion and high temperatures (melting point near 3,700°F), making it ideal for use in high performance pumps and valves. Aluminum oxide is also resistant to corrosion and chemical attack, making it an ideal choice for use in harsh environments. In addition, aluminum oxide is electrically insulating and has a low coefficient of friction. It is the ideal surface for corona treating rollers.

Chrome Oxide

As a ceramic, chrome oxide is extremely hard and dense. This makes it highly resistant to wear, both from sliding and from abrasive particles. Additionally, its low coefficient of friction makes it ideal for applications where there is a risk of adhesive wear, such as in corrosive environments. Because of these properties, chrome oxide is commonly used in a wide range of industrial applications where leak-proof seals are essential. It can be sprayed onto most metallic surfaces for added protection, and can be ground to a smooth finish. 

Abrasion Resistant Coating & Wear Resistant Coating FAQ's