DOMite - CQMS Razer
Transcription
DOMite - CQMS Razer
DOMite ® Extreme resistance plus protection Long-life Domite® offers the ultimate in protection for extreme applications resulting in increased production, less down time + reduced maintenance costs DOMITE ® Long-life DOMITE® offers the ultimate in protection for extreme applications resulting in increased production, less down time + reduced maintenance costs. Extreme protection for extreme applications Extend your ASSET life and reduce your maintenance costs Domite® is a combination of high chromium white iron metallurgically bonded to a mild steel backing plate. The white iron has a nominal hardness of 700 Brinell (63 Rc) providing maximum abrasion resistance protection for your equipment. The mild steel is easily weldable with minimal preparation and acts as a cushion for the white iron, enabling it to handle impact and abrasion in the most extreme applications. This unique product was created for the Australian mining and quarry industries by Mason & Cox Pty Ltd in 1971 and is now manufactured and marketed worldwide through authorised distributors for CQMS Razer. Technical specifications Domite® has established a reputation as the solution for impact and high abrasion in the mining and quarry industries, and has numerous applications in the sugar cane, recycling, cement, mineral processing and dredging industries among others. backing plate achieving a high strength joint. White iron: modified AS2027 15/3 PROVEN IN THE FIELD Lamination of chrome moly white iron metallurgically bonded to a mild steel Cr Mo with finished nominal hardness of 700 HB (63 Rc) and containing primary carbides up to 1500HV. 8 success stories using DOMITE® wear packages designs and layouts Gyratory Primary crusher, Svelda 60x89, Spider arms and hub are enhanced with Domite® buttons, chocky bars and skid bars and thus gives a considerable increase in wear life Surge bin protection using 50mm square bars, DLP 1101, DLP 125, to create dead-box effect, supplied on large pre-made panels. Still in service after 10 years 3 1 2 Chute lined with Domite® Mk2 Rock box liners 2 4 Arm guard liners for a 60x89 Superior Cone crusher protection, with custom Domite® parts welded to cast steel frames, giving years of protection Dragline/shovel bucket protection Loader/excavator bucket protection Chute liners/rock box bars Feeder pan liners Quarry and mining grizzly screens Shredder/grinder tips Cane knife edges Adaptors wear caps Dredging industry DOMITE® RUBBADEX® An acoustic wear plate for abrasion and impact applications, RUBBADEX® combines DOMITE® with a rubber backing to achieve wear resistance and noise reduction properties in one. Quality Endorsed Products to IS09000-2000 Certificate of compliance report supplied upon request Services and products Product Range Domite® is available in over 2,500 standard shapes and sizes and can be used in combination to protect any impact and high CQMS Razer continues to supply a large range of unique wear products to mine sites in Australia and worldwide. We offer to all our clients the following range of services for long life, reliable wear solutions. These are: abrasion areas. In addition, certain Domite® products can be cut or bent to suit application, prior to welding, to help customise the protection on the machine. Custom Domite® parts can be designed to user’s specifications. Domite® – a laminated, abrasion resistant wear product at 700 HB Technical Support and Advice Rubbadex® – a wear resistant, noise reduction, wear plate Offer long life wear solutions, based on existing successful applications Liner material upgrade and improvement Product Service and Size Design capability and recommendations Fast delivery and service Wear audits in liaison with mine and design personnel Standard and custom-made parts available Regular visits and inspections to discuss wear problems and solutions An extensive range of sizes existing On-site product trials to prove product performance Large stocks of pieces ready for assembly Wear packages, design and layouts for draglines, excavators, Tungsten Carbide enhanced wear products rope shovels and dippers Emergency supply conditions possible, through negotiation Domite® Wear protection on Tunnel borer Dredge pump wear plate in Domite® up to 2.2m diameter, which can outperform AR 400 steel by 5 times 5 7 6 Coal sizer using Domite® tips, replacing conventional hard-facing and high labour maintenance costs 8 Dredge blocks on suction Drag head replacing Nihard castings which would wear out prematurely or fall off 11 2 3 Chocky bars • Most popular for replacing hardfacing and clad plate • Available with or without notched backing plate • Easy to cut and shape over contoured surfaces See pages 12 and 13 for procedures Wear Buttons + Donuts Standard Wear Bars • Ideal for smaller areas requiring wear resistant material • Requires less welding time and material than conventional wear plate See pages 12 and 13 for procedures • Popular for rock-box protection, impact areas and transfer points • Chute protection in both low and high stress abrasion • Many other shapes and sizes available See pages 12 and 13 for procedures Extend your ASSET life and reduce your maintenance costs 4 DIMENSIONS PART A B 240 C D E 40 WEIGHT kgs CB25N 240 25 15 8 23 0.9 CB40N 240 40 15 8 23 1.5 CB50N 240 50 15 8 23 1.9 CB65N 240 65 15 8 23 2.5 CB90N 240 90 15 8 23 4.0 CB100N 240 100 15 8 23 4.3 CB130N 240 130 15 8 23 5.6 A TOP VIEW 15 15 23 23 8 8 SIDE VIEW (NOTCHED - CHOCKY BAR) SIDE SIDE VIEW VIEW (STANDARD (STANDARD - CHOCKY - CHOCKY BAR) BAR) A A DIMENSIONS PART A B C D E WEIGHT kgs WB60 60 40 20 10 30 0.7 WB75 75 55 20 10 30 1.0 WB90 90 70 20 10 30 1.5 A WEAR BUTTONS A TOP VIEW WB115 115 95 20 12 32 2.6 WB150 150 130 25 16 41 5.7 TOP VIEW B B C E C E D D SECTION A-A SIDE VIEW DONUTS DLP1920 75 25 17 8 25 0.7 DLP1921 100 50 17 8 25 1.0 DLP1994 100 70 24 8 32 1.0 DLP2196 130 80 15 8 23 1.3 DIMENSIONS C D PART A B C D E WEIGHT kgs DLP919 200 25 15 10 25 1 .0 DLP1191 300 25 15 10 25 1.5 DLP295 153 38 25 8 33 1.5 DLP4 300 38 25 8 33 3.0 DLP184 150 75 29 10 39 3.4 DLP337 127 51 38 12 50 2.5 DLP369 210 50 38 12 50 4.1 E DLP125 230 50 38 12 50 4.5 SIDE VIEW DLP201A 432 50 38 12 50 8.5 DLP1101 150 50 40 10 50 2.9 DLP343 190 50 40 10 50 3.7 DLP453 294 50 40 10 50 5.5 DLP2017 300 50 40 10 50 5.9 DLP352 206 203 38 20 58 19.0 DLP392/20 241 100 38 28 58 11.0 DLP619 150 75 50 10 60 5.3 DLP5008 300 100 75 25 100 23.6 DLP5009 454 100 75 25 100 35.6 A B TOP VIEW Contact CQMS Razer for price and availability 11 5 2 Designed specifically for chutes, bins, transfer points and hoppers which handle and store fine, crushed ores DOMIte® Microledge • Creates a “dead-box” effect in these applications, extending the maintenance life of bins, chutes, transfer points and hoppers, with ore on ore wear effect • Reduces the need for added wear plate inventory and costs in these applications • Cost effective wear solution and ease of installation and use See pages 12 and 13 for procedures Standard Wear Plates 6 Standard wear plates are used in specific wear applications providing excellent protection of • Chutes and Conveyor transfer points DIMENSIONS PART LENGTH WIDTH THICKNESS SDP304 128 50 50 WEIGHT kgs 3.6 SDP296 190 50 50 5.5 SDP299 210 50 50 6.0 SDP297 230 50 50 6.6 SDP298 432 50 50 12.5 Five popular sizes available or custom designed to suit specific needs ISOMETRIC VIEW 30 25 65 B C 22x44 SLOTS TYP. 35 50 BACK-WELDING 40 To accommodate a wear surface requiring more than one Domite® piece, CQMS RAZER offers back-welding, a process of welding two or more pieces of Domite® together on the mild steel backing plates, to form larger plate sizes and coverage: A 50 FRONT VIEW SIDE VIEW Arcstuds can be applied to all Domite® products as required D DIMENSIONS PART A B C C D E A WEIGHT kgs DLP5701 300 450 20 10 30 31.8 DLP4677 300 300 20 10 30 21.2 DLP4682 300 150 20 10 30 10.6 DLP5894 300 300 30 10 40 28.3 DLP4895 300 150 30 10 40 14.1 B Wear liners can be manufactured to custom shapes and sizes. Refer CQMS Razer. Nelson studs are fitted according to customer satisfaction. E SIDE VIEW TOP VIEW Contact CQMS Razer for price and availability 7 2 11 • Far superior to standard Q&T wear plates offering greater wear life SKID BARS • Available in straight, herringbone or domed shapes • Geometrically designed to increase wear life • Excellent for bucket protection and fixed plant applications See pages 12 and 13 for procedures • The table highlights the list of standard Grizzly bars Grizzly Bars • Custom-made Grizzly bars are available on request • Significantly improved wear life and reduced downtime See pages 12 and 13 for procedures • Cost effective as compared to hard facing Shredder /Grinder Tips • Superior edge retention and sharpness • No need to rebuild edges • Increased production and cutting efficiency • Easy to install and maintain See pages 12 and 13 for procedures 8 DIMENSIONS PART TYPE A B 12 TYP. E C D E C 16 TYP. WEIGHT kgs C E C D E D D 17 TYP. RECTANGULAR SIDE VIEW SB403 1 214 101 22 12 34 5.1 SB406 1 302 101 22 12 34 7.3 SB409 1 154 101 22 12 34 3.7 SB205 1 279 75 22 12 34 6.1 45° SIDE VIEW SIDE VIEW A A A 60° HERRINGBONE SB404L 2 214 101 22 12 34 5.9 SB405R 2 214 101 22 12 34 5.9 SB407L 2 302 101 22 12 34 8.4 SB408R 2 302 101 22 12 34 8.4 SB410L 2 154 101 22 12 34 4.2 SB411R 2 154 101 22 12 34 4.2 B TOP VIEW B B TOP VIEW TOP VIEW DOMED EDGE SB412 3 250 150 20 25 45 13.1 SB413 3 200 150 20 25 45 10.5 SB414 3 250 250 20 25 45 21.9 DIMENSIONS PART A B C D E F WEIGHT kgs TYPE A - 150/50 TAPER A DLP2067 305 150.0 137.5 38 12 50 13.6 DLP2068 305 137.5 125.0 38 12 50 12.5 DLP2069 305 125.0 112.5 38 12 50 11.2 DLP2070 305 112.5 100.0 38 12 50 10.0 DLP2071 305 100.0 87.5 38 12 50 8.8 DLP2072 305 87.5 75.0 38 12 50 7.5 DLP2073 305 75.0 62.5 38 12 50 6.3 DLP2074 305 62.5 50.0 38 12 50 5.1 DLP2075 305 150 141 38 12 50 13.8 DLP2076 305 141 131 38 12 50 12.9 DLP2077 305 131 122 38 12 50 11.9 DLP2078 305 122 113 38 12 50 11.1 DLP2079 305 113 103 38 12 50 10.1 DLP1886 311 76 66.5 38 12 50 6.6 DLP1887 311 67 57.0 38 12 50 5.6 DLP1888 311 57 47.5 38 12 50 4.7 DLP1889 311 48 38.0 38 12 50 3.8 D B E C F TOP VIEW SIDE VIEW TYPE B - 150/75 TAPER 76/38 TAPER DIMENSIONS PART TYPE A B C D E F G WEIGHT kgs DLP653 1 90 90 25 20 45 7/8"-14 UNF 40.0 2.9 C DLP920 1 90 50 25 20 45 7/8"-14 UNF 40.0 1.6 D PLAIN DLP996 1 50 50 20 18 38 3/4"-16 UNF 32.0 0.7 DLP1052 1 80 80 25 20 45 7/8"-14 UNF 40.0 2.4 DLP1115 1 100 100 25 20 45 7/8"-14 UNF 40.0 3.6 DLP1208 1 64 64 20 20 40 3/4"-16 UNF 31.3 1.2 DLP1340 1 80 56 25 20 45 M20 x 1.5P 35.0 1.6 DLP1654 2 90 90 30 20 50 7/8"-14 UNF 40.0 3.0 DLP2038 2 80 56 30 20 50 M20 x 1.5P 35.0 1.8 E C C TYPE 2 SECTION A-A F G TYPE 1 SECTION A-A TYPE 3 SECTION A-A FLARED B A A BUTTERFLY DLP1927 3 90 90 35 20 55 7/8"-14 UNF 40.0 3.1 DLP2014 3 90 50 35 20 55 7/8"-14 UNF 40.0 1.8 DLP2039 3 80 56 35 20 55 M20 x 1.5P 35.0 1.9 TOP VIEW Contact CQMS Razer for price and availability 9 • Cost effective as compared to hard facing KNIFE EDGES • Superior edge retention and sharpness • No need to rebuild edges • Increased production and cutting efficiency • Easy to install and maintain See pages 12 and 13 for procedures • Metallurgically bonded martensitic white iron bonded to a weldable, impact resistant backing plate offering superior wear wafer strips • Manufactured to be easily cut and shaped to fit over contoured surfaces • Thinner and lighter than standard Domite® chocky bars • Significant increase in wear life and less downtime See pages 12 and 13 for procedures 10 DIMENSIONS PART TYPE A B C D E WEIGHT kgs DLP1065-16 1 203 16 38 12 50 0.9 DLP1065-19 1 203 19 38 12 50 1.1 DLP1065-22 1 203 22 38 12 50 1.3 DLP1065-25 1 203 25 38 12 50 1.5 DLP1265-16 1 305 16 38 12 50 1.4 DLP1265-19 1 305 19 38 12 50 1.6 DLP1265-22 1 305 22 38 12 50 1.9 DLP1265-25 1 305 25 38 12 50 2.2 ARROWHEAD A E HALF ARROWHEAD DLP1065A-16 2 203 16 38 12 50 1.0 DLP1065A-25 2 203 25 50 12 62 1.7 DLP1265A-25 2 305 25 40 16 56 2.5 DLP1301-19 3 203 19 38 12 50 1.6 DLP1301-25 3 203 25 38 12 50 2.1 DLP1301-28 3 203 28 38 12 50 2.3 FRONT VIEW BLUNT C D B TYPE 1 TYPE 2 TYPE 3 SIDE VIEWS DIMENSIONS PART TYPE A 240 WEIGHT kgs WS25N NOTCHED 25 0.6 WS40N NOTCHED 40 0.9 WS50N NOTCHED 50 1.2 WS65N NOTCHED 65 1.6 40 TYP. A TOP VIEW 66 12 12 66 SIDE SIDEVIEW VIEW(STANDARD (STANDARD--WAFER WAFERSTRIP) STRIP) SIDE VIEW (NOTCHED - WAFER STRIP) Contact CQMS Razer for price and availability 11 2 DOMite® Welding Procedure Cutting Details High pressure abrasive water jet cutting is the preferred cutting method. Thermal cutting using an oxyacetylene torch, arc-air or plasma is NOT recommended due to high localized heat input and high risk of cracking and delamination. For Domite® no greater than 25mm section thickness, cutting by abrasive disc is an accepted practice. CAUTION. Extreme care must be taken when cutting to minimise local pre-heating or cracks and delamination may occur. Cutting Procedure 25mm Section Thickness 1 Secure the Domite® piece to be cut in a vice or clamp 1 Ensure that the Domite® backing plate and mating metal surface is clean and flat 2 Welding Rod selection – Low hydrogen weld rods or gas covered cored wire is recommended Gas shielded solid MIG wire – Ø 1.2mm max Flux cored wire – Ø 1.6mm max to ASTM/AWS A5.18 classification ER705-6 Low hydrogen electrode – Ø 3.25mm max to ASTM/AWS A5.1 classification E7016-1H8 or E7018-1H4 3 Do not pre-heat Domite® 4 Clamp and tack weld Domite® into position 5 Stitch weld, laying 50mm maximum length on each run, alternating ends or sides to minimize heat input 6 Do not deposit weld within 2mm from joint line between Domite® and steel backing plate, as shown in (Fig 1) 2 Notch the backing plate as shown in (Fig 1) 3 Notch the White Iron a minimum of 3mm deep opposite the notch in the backing plate, as per (Fig 2) 4. Wrap the Domite® with a rag and carefully hit using a soft faced hammer. The piece should break cleanly at the notch Note: The deeper the notch in the White Iron, the cleaner the break. 12 2 CAUTION. Temperature must not exceed 200°C. Excessive heat input may cause cracking and delamination. Use thermal crayons to monitor temperature. Do not weld continuously. Continuous weld may cause warping, delamination, and cracking. If a complete peripheral weld is required, use stitch weld procedure as per step 5. Product safety Forming Procedure This practice is suitable for Chocky bars only. Any fitting or fabrication work should be carried out in accordance with applicable site safety standards, ensuring use of approved hard hats, eye protection, steel-toed shoes and protective gloves. Always use a soft faced hammer when performing the work as descri bed in these instructions. NOTE: For severe curves with a radius of less than 305mm, or inside curves, it is advisable to notch the mild steel backing plate opposite the ‘V’ to assist forming. (Fig A) The Chocky Bar may crack during bending. This is normal. 1 Clean the surface to which chocky bar will be welded 2 Tack weld one end of the chocky bar (as per the welding procedure) in at least 3 places by 15mm minimum length per weld (Fig 1) Outside Curves: Hammer down unwelded end of bar with a soft face hammer to bend bar to match mating radius (Fig 2) Inside curves: Starting in the center strike bar with a soft face hammer to bend bar to match mating radius (Fig 3) 3 Stitch weld as per the weld procedure 13 2 11 RUBBADEX® WEAR PLATES A patented acoustic wearplate that provides all the wear-resistance and impact benefits of Domite® together with effective noise suppression layer of wear resistant rubber or polymer. Rubbadex® was developed by CQMS Razer in response to the growing pressure for quieter materials-handling environments. The unique rubber bond in this composite heavy-duty wear plate suppresses noises generated by material impact by up to 13 dbA. The steel backing plate and rubber sandwich impart toughness to the white iron, and reduce vibration transmitted to the supporting structure. Rubbadex® is acknowledged for its durability and is backed by CQMS Razer’s commitment to customer service. Applications Technical Specifications • Crusher feed cones • Impact chutes • Storage and feed hoppers • Gyratory crusher feed plates Lamination of chrome moly white iron attached to a mild steel backing plate using a rubber bonding layer to achieve a high strength joint. White iron: Modified AS2027 15/3 Cr Mo with finished hardness 650 HB min (62 Rc). • Easy to weld using mild steel • Backing plate Product Range • Bolt directly through pre-cast holes • Bolt directly using pre-attached studs Fixings Made to customer’s requirements. Plate sizes typically up to 1.25m2 with wear plate. A range of standard Rubbadex® wear plates are available. Plate thickness 30mm to 50mm. A B 52 F TOP VIEW DIMENSIONS PART A B C D E F MCR314 300 300 32 6 8 6 WEIGHT kgs 28.8 MCR315 300 150 32 6 8 6 14.0 C D E SIDE VIEW Contact CQMS Razer for price and availability 14 High Stress gouging abrasion test data 0.9 TYPE Wear factor THICK - MM HARDNESS - HB Rolled reference Q&T100 steel 19.05 240 ASTM A 514 Grade B Structural steel Q&T100 25.40 232 ASTM A 514 Grade B AR400 19.05 384 AR450 19.05 390 AR500 19.05 462 AR600 19.05 552 Austenitic manganese steel casting MnSt 19.05 205 Solution treated ASTM A 128 Grade A White Iron castings CrMo WI 19.05 730 ASTM A532 11B (WCI) (15% Cr 3% Mo 3% C) iron plates 755 ASTM A532 11B (15% Cr 3% Mo 3% C) WCI brazed to a steel backing plate 640 Proprietary hypereutectic high Cr WCI brazed to a steel backing plate 0.8 0.7 0.6 0.5 0.4 0.3 Rolled AR steel 0.2 0.1 Do m Ru ite bb ® ad Cr ex Mo La Cr WI m CD .H yp O L er C Cr R® CS Hy O pe L rC R® W C1 AR * 60 0 W C3 AR * 50 0 M nS AR t 45 AR 0 40 0 W C2 * 0.0 TYPE/ IDENTITY • ASTM G81 Assessment • Wear ratio/factor (F) for each plate Laminated White Iron plates Domite® 25.4 Laminated 19.05 Hyperchrome® White Iron / laminate Impact Data Typical results of non-standard IZOD impact test carried out on 16 x 10mm unnotched specimens. Ratio of White Iron/Steel in laminated specimens was 3:1. A B C 15/3 Cr/Mo Brazed to mild steel backing 15/3 Cr/Mo Brazed to quenched & tempered steel backing ASTM A 514 Grade B SAE4150 Casting, oil quenched & tempered Vickers Hardness 406 927 927 490 Average impact – Joules 18 156 233 250 Material Rubbadex 25.4 750 CrC SOL 25.4 564 6.4mm thick single pass ~30%Cr 4%C bal. Fe deposit. CrC DOL 25.4 595 9.6 mm thick, double pass ~30%Cr4%C bal. Fe deposit. WC 1 19.05 478 4mm thick 60Wt.%, cast overlays carbide & crushed (eutectic) 397 4mm thick 60Wt.% macrocrystalline (monolithic) WC in a 30HRC nickel alloy matrix 491 4mm thick 60Wt.% macrocrystalline (monolithic) WC in a 50HRC nickel alloy matrix CrC weld overlays PTAW tungsten CMnB abrasion resistant (AR) steels, quenched & tempered to various nominal hardness levels. ASTM A532 11B rubber laminate (15% Cr 3% Mo 3% C) WCI bonded to a rubber / steel layer DESCRIPTION 15/3 – Cr/ Mo Plain Casting, annealed DESCRIPTION WC 2 WC 3 19.05 19.05 A = Results are for plain White Iron casting without a backing plate B = Results reveal that the impact properties of Domite® is significantly enhanced with addition of a brazed, mild steel backing plate C = The addition of a quenched and tempered steel backing plate further enhances Domite® impact properties by a further 50% and is comparable to a high strength chrome-moly steel in the fully heat treated condition * Independent testing carried out by Amdel Laboratories 15 2 11 Down to earth service + support Our complete Plate, Block and Wear range is backed up by fast delivery and the highest level of service and support. We offer regular on-site inspections, wear audits and performance evaluations to identify appropriate, cost-effective wear solutions to meet client needs. extensive capability in product design and development regular visits, wear audits and inspections to discuss wear problems and solutions on-site product trials for proven performance liner material upgrades and improvements clear technical data sheets to support in-field use complete wear packages including design and layouts for draglines, excavators, rope shovels and dippers Technical expertise + advice We have the product knowledge, technical innovation and expertise to develop specifications for all your specialty and custom wear products. Our technical team offers: From mining, milling and smelting, to bulk materials handling and more, CQMS Razer’s FIXED PLANT division meets the needs of multiple industries. We design and manufacture a range of plate, block and wear products, stone dusting systems, conveyor accessories and fabrications for specific projects and applications. Tunnel Boring Machine (TBM) operating in Gotthard tunnel project in Europe, which is the longest tunnel ever constructed in the world. There are 4 tunnels in total, each being 59 km long and each having a TBM operating from each end and each TBM were either completely Lamitized or partly protected with DOMITE®. The project took 10 years and is nearly completed. DOMITE® achieved a superior wear life over AR 450 BHN hardness steels by a factor of at least 5 times and thus saved the contractors millions of $ in less downtime and TBM maintenance during the project life. Please check our website for current contact details. Offices in: www.cqmsrazer.com BRISBANE MARYBOROUGH DALLAS NEWCASTLE DONGYING CITY PERTH HONG KONG SANTIAGO MACKAY SYDNEY CQMS Razer is committed to safety, quality and the environment. We embrace sustainable manufacturing processes and materials to minimise emissions, reduce waste and improve the safety of our people and clients. We work to ISO 9001 quality assurance standards across all of our operations and actively support regional and remote communities with local programs and initiatives.