DOMITE - Creighton Rock Drill Ltd.
Transcription
DOMITE - Creighton Rock Drill Ltd.
DOMITE LAMINITE LAMINITE RUBBADEX The tough original REMAR DOMITE LAMINITE Laminite® – 700HB Extreme protection for extreme applications APPLICATIONS • • • • • • • • • Dragline/Shovel Bucket Protection Loader/Excavator Bucket Protection Chute Liners/Rock Box Bars Feeder Deck Plates Quarry and Mining Grizzly Screens Shredder/Grinder tips Cane knife edges Adapters Wear Caps Dredging industry TECHNICAL SPECIFICATIONS Lamination of chrome moly white iron metallurgically bonded to a mild steel backing plate achieving a high strength joint. White iron: modified AS2027 15/3 Cr Mo with finished minimum hardness of 700 HB (63 Rc) and containing primary carbides up to 1500HV. Laminite® is a combination of high chromium white iron metallurgically bonded to a mild steel backing plate. The white iron has a minimum 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 world wide through authorised distributors for PAC Mining Pty Ltd (trading as Domite and Related Technologies). Laminite® 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. Laminite® is available in over 2,500 standard shapes and sizes and can be used in combination to protect any impact and high abrasion areas. In addition, certain Laminite® products can be cut or bent to suit application, prior to welding, to help customise the protection on the machine. Custom Laminite® parts can be designed to user’s specifications. Long-life Laminite® offers extreme protection for extreme applications resulting in increased production, less down time and reduced maintenance costs. Services and products PAC Mining Pty Ltd (trading as DART) 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: Technical Support and Advice • Offer long life wear solutions, based on existing successful applications • Liner material upgrade and improvement • Design capability and recommendations • Wear audits in liaison with mine and design personnel • Regular visits and inspections to discuss wear problems and solutions • On-site product trials to prove product performance • Wear packages, design and layouts for Draglines, excavators, rope shovels and dippers. Product Range • Laminite– a laminated, abrasion resistant wear product at 700 HB • Remar – a reinforced, abrasion resistant white iron at 650 HB • Rubbadex – a wear resistant, noise reduction, wear plate • Tungsten Carbide enhanced wear products Product Service and Size • Fast delivery and service • Standard and custom-made parts available • An extensive range of sizes existing • Large stocks of pieces ready for assembly • Emergency supply conditions possible, through negotiation Quality Endorsed Products to IS09000-2000 • Certificate of compliance report supplied upon request 2 Wear Buttons & Donuts Chocky Bars Dimensions Part Number CB 25 CB 25N CB 40 CB 40N CB 50 CB 50N CB 65 CB 65N CB 100 CB 100N CB 130 CB 130N Type 1 2 1 2 1 2 1 2 1 2 1 2 A 240 240 240 240 240 240 240 240 240 240 240 240 B 25 25 40 40 50 50 65 65 100 100 130 130 C 15 15 15 15 15 15 15 15 15 15 15 15 Dimensions D 8 8 8 8 8 8 8 8 8 8 8 8 E 23 23 23 23 23 23 23 23 23 23 23 23 Weight KG 0.9 0.9 1.5 1.5 1.9 1.9 2.5 2.5 3.9 3.9 5.2 5.1 • Most popular for replacing hardfacing and clad plate. • Available with or without notched backing plate. Wear Buttons WB 60 WB 75 WB 90 WB 115 WB 150 Donuts DLP 1920 DLP 1921 DLP 1994 DLP 2196 A 60 75 90 115 150 B 40 50 45 95 130 C 12 17 17 20 25 D 10 10 10 12 16 E 22 27 27 32 41 Weight KGs 0.5 0.9 1.2 2.6 New! 5.7 New! 75 100 100 130 25 50 70 80 17 17 24 15 8 8 8 8 25 25 32 23 0.7 1.0 1.0 1.3 New! • Ideal for smaller areas requiring wear resistant material • Requires less welding time and material than conventional wear plate • Easy to cut and shape over contoured surfaces. See pages 10 and 11 for procedures. 3 DOMITE LAMINITE Standard Wear Bars Standard Wear Plates Dimensions Dimensions Part Number DLP 919 DLP 1191 DLP 200 DLP 515 DLP 1059 DLP 4 DLP 295 DLP 658 DLP 508 DLP 201 DLP 125 DLP 201A DLP 369 DLP 452 DLP 453 DLP 1101 DLP 2230 DLP 270 DLP 271 DLP 337 DLP 965 DLP 205 DLP 184 DLP 569 DLP 528 DLP 619 DLP 450 DLP 451 DLP 392/20 A 200 300 102 195 95 300 153 240 190 432 230 432 210 254 294 150 600 254 203 127 250 279 150 200 150 150 294 194 241 B 25 25 33 25 25 38 38 40 50 50 50 50 50 50 50 50 50 51 51 51 60 75 75 75 75 75 80 80 100 C 15 15 25 20 20 25 25 22 20 34 38 38 38 40 40 40 38 12 12 38 12 25 29 29 40 50 38 38 38 D 10 10 8 10 10 8 8 16 10 12 12 12 12 10 10 10 12 8 8 10 8 12 10 10 10 10 12 12 20 E 25 25 33 30 30 33 33 38 30 46 50 50 50 50 50 50 50 20 20 48 20 37 39 39 50 60 50 50 58 Weight KGs 1 .0 1.5 0.9 1.1 0.6 3.0 1.5 2.9 2.2 7.8 4.5 8.5 4.1 5.0 5.8 2.9 11.8 New! 2.0 1.6 2.4 2.4 6.1 3.4 4.6 4.4 5.3 9.2 New! 6.1 New! KGs 18 6 24 8.6 18 10 28 13.2 203 38 20 58 19.0 B C DLP 995 305 150 DLP 1213 301 200 DLP 352 206 DLP 727 294 294 20 8 28 19.0 DLP 1(MOD) 300 300 20 10 30 21.2 DLP 2 372 372 20 8 28 30.4 DLP 692 445 294 20 8 28 28.8 DLP 667 445 445 19 6 25 38.9 New! DLP 1935 190 212.5 17 8 25 10.0 DLP 2002 241 290.5 22 8 30 New! New! Trapezoidal 50 80 19.5 New! To accommodate a wear surface requiring more than one Laminite® piece, PAC offers back-welding, a process of welding two or more pieces of Laminite® together on the mild steel backing plates, to form larger plate sizes and coverage: Arcstuds can be aplied to all Laminite® products as required B D A G E A Laminite Back-Welding C E F D Number 11.0 • 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 4 Weight Part 3 Laminite Star Plate – as supplied in one piece Laminite® Micro-ledge Part Number New! Length (mm) Width (mm) Thickness (mm) Weight (kg) SDP 304 128 50 50 3.6 SDP 296 190 50 50 5.5 SDP 299 210 50 50 6.0 SDP 297 230 50 50 6.6 SDP 298 432 50 50 12.5 Laminite Star Plate – after pressing and breaking • Designed specifically for chutes, bins, transfer points and hoppers which handle and store fine, crushed ores • 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 • Five popular sizes available or custom designed to suit specific needs • Cost effective wear solution and ease of installation and use 186mm 30mm typical 34mm x 22mm typical 186mm T 30mm typical L W 50 35 65 25 40 50 Laminite® Star Plates Patent Pending New! Star Plate – the multi-shaped wear resistant plate!!! The Star plate concept is based on a one size for most applications to suit chute, bin, hopper, bucket and truck bed linings and offers a very cost effective, extremely long wear life alternative to standard Chrome-carbide clad sheets and AR wear plates which have to be cut and shaped using special tools and equipment. Features • Standard size at 400mm square by 23mm thick to suit most linings • Cast notches on wear surface corresponding to slotted backing plate to allow ease of breaking under force • One standard plate produces many different sizes and shapes • Beveled edges to reduce hanging of material and chipping /spalling of edges • 700 HB wear plates offering superior wear and impact resistance when compared to Chrome carbide clad plate • Designs and shapes can be modified to suit specific needs Benefits • Ease of use and installation • Extended wear life when compared to the AR plates and Chrome carbide plates • Reduces total weight of liners required when compared to AR plates • Reduced liner inventory required for installation and repairs for all applications • Less downtime and maintenance • Ability to replace worn individual sections rather than whole plates or sheets • Cost effective due to extended wear life 5 DOMITE LAMINITE Grizzly Bars Skid Bars Dimensions Rectangular Type SB 403 1 SB 406 1 SB 409 1 Herringbone SB 404L 2 SB 405R 2 SB 407L 2 SB 408R 2 SB 410L 2 SB 411R 2 Domed Edge SB 413 3 SB 412 3 SB 414 3 Dimensions A 214 302 154 B 101 101 101 C 22 22 22 D 12 12 12 E 34 34 34 Weight KGs 5.1 7.3 3.7 214 214 302 302 154 154 101 101 101 101 101 101 22 22 22 22 22 22 12 12 12 12 12 12 34 34 34 34 34 34 5.9 5.9 8.4 8.4 4.2 4.2 200 250 250 150 150 250 20 20 20 25 25 25 45 45 45 10.5 New! 13.1 New! 21.9 New! • Far superior to standard Q & T wear plates offering greater wear life • Available in straight, herringbone or domed shapes Type 1 A B TYPE A - 150/50 TAPER DLP 2067 305 150.0 DLP 2068 305 137.5 DLP 2069 305 125.0 DLP 2070 305 112.5 DLP 2071 305 100.0 DLP 2072 305 87.5 DLP 2073 305 75.0 DLP 2074 305 62.5 TYPE B - 150/75 TAPER DLP 2075 305 150 DLP 2076 305 141 DLP 2077 305 131 DLP 2078 305 122 DLP 2079 305 113 DLP 2080 305 103 DLP 2081 305 94 DLP 2082 305 84 C D E F Weight KGs 137.5 125.0 112.5 100.0 87.5 75.0 62.5 50.0 38 38 38 38 38 38 38 38 12 12 12 12 12 12 12 12 50 50 50 50 50 50 50 50 13.6 12.5 11.2 10.0 8.8 7.5 6.3 5.1 141 131 122 113 103 94 84 75 38 38 38 38 38 38 38 38 12 12 12 12 12 12 12 12 50 50 50 50 50 50 50 50 13.8 12.9 11.9 11.1 10.1 9.2 8.3 7.4 • The above table highlights the list of standard Grizzly bars available off the shelf • Custom-made Grizzly bars are available on request Type 2 Type 3 6 Knife Edges Shredder/Grinder Tips Dimensions Type PLAIN DLP 653 1 DLP 920 1 DLP 996 1 DLP 1052 1 DLP 1115 1 DLP 1208 1 DLP 1340 1 FLARED DLP 1654 2 DLP 2038 2 BUTTERFLY DLP 1927 3 DLP 2014 3 DLP 2039 3 Dimensions A B C D E F G Weight KGs 90 90 50 80 100 64 80 90 50 50 80 100 64 56 25 25 20 25 25 20 25 20 20 18 20 20 20 20 45 45 38 45 45 40 45 7/8"-14 UNF 7/8"-14 UNF 3/4"-16 UNF 7/8"-14 UNF 7/8"-14 UNF 3/4"-16 UNF M20 x 1.5P 40.0 40.0 32.0 40.0 40.0 31.3 35.0 2.9 1.6 0.7 2.4 3.6 1.2 1.6 90 80 90 56 30 30 20 20 50 50 7/8"-14 UNF M20 x 1.5P 40.0 35.0 3.0 1.8 90 90 80 90 50 56 35 35 35 20 20 20 55 55 55 7/8"-14 UNF 7/8"-14 UNF M20 x 1.5P 40.0 40.0 35.0 3.1 1.8 1.9 • Cost effective as compared to hard facing • Superior edge retention and sharpness • No need to rebuild edges • Increased production and cutting efficiency • Easy to install and maintain ARROWHEAD Type DLP 1065-16 1 DLP 1065-19 1 DLP 1065-22 1 DLP 1065-25 1 DLP 1265-16 1 DLP 1265-19 1 DLP 1265-22 1 DLP 1265-25 1 HALF ARROWHEAD DLP 1065A-25 2 DLP 1265A-25 2 BLUNT DLP 1301-19 3 DLP 1301-25 3 DLP 1301-28 3 A 203 203 203 203 305 305 305 305 B 16 19 22 25 16 19 22 25 C 38 38 38 38 38 38 38 38 D 12 12 12 12 12 12 12 12 E 50 50 50 50 50 50 50 50 Weight KGs 0.9 1.1 1.3 1.5 1.4 1.6 1.9 2.2 203 305 25 25 50 40 12 16 62 56 1.7 2.5 203 203 203 19 25 28 38 38 38 12 12 12 50 50 50 1.6 2.1 2.3 • Cost effective as compared to hard facing • Superior edge retention and sharpness • No need to rebuild edges • Increased production and cutting efficiency • Easy to install and maintain Shaped Wear Bars Dimensions DLP 160 DLP 384 DLP 753 Type 2 1 1 A 275 200 244 B 5 13 10 C 16 20 25 Type 1 D 21 20 25 E 8 10 10 F 29 30 35 Weight KGs 0.9 0.8 1.4 Type 2 7 Domite DOMITE LAMINITE Bending Details DLP 1935 Wear Bars DLP 1935 Wear Bars after 8,000 hours CB13 Wear Bars CB13 Wear Bars after 9,000 hours A selection of Laminite® applications. 8 Typical success story using LAMINITE® wear packages using our designs and layouts...Let us review your needs and extend your bucket life and reduce your maintenance costs!!! 1. 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. 2. Hub liners for a large crusher, 12 segments per set, replacing Cr/Mo steel which lasted only 6 months. 3. Primary crusher, Svedala 60x89, Spider arms and hub are enhanced with LAMINITE® buttons, chocky bars and skid bars. The steel castings the LAMINITE® protects have been in service for 5 years, negating the need to have extra inventory. 4. Arm guard liners for a 60x89 Superior Cone crusher protection, with custom DOMITE® parts welded to cast steel frames, giving years of protection. 5. Coal sizer using LAMINITE® tips, replacing conventional hard-facing and high labour maintenance costs. 6. Road Planer machine with CB40 chocky bar sections which replaced and outlast conventional hard-facing. 7. Dredge Pump plate in LAMINITE®, up to 2.2m diameter, replaced AR 400 plates which lasted only a few months of continued operation. 8. Dredge blocks on suction Drag head replacing Nihard castings which would wear out prematurely or fall off. 1 2 3 4 5 6 7 8 9 Domite DOMITE LAMINITE Bending Details Laminite® Cutting Details Laminite® Welding Procedure 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. 1. Ensure that the Laminite® 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 t ASTM/AWS A5.1 classification. E7016-1H8 or E7018-1H4 3. Do not pre-heat Laminite® . 4. Clamp and tack weld Laminite® 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 Laminite® and steel backing plate, as shown in Figure 1. For Laminite® 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 Laminite® piece to be cut in a vice or clamp. 2. Notch the backing plate as shown in Figure 1. 3. Notch the White Iron a minimum of 3mm deep opposite the notch in the backing plate, as per Figure 2. 4. Wrap the Laminite® 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. 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. Welding procedure Fig. 1 Cut notch to be a min. of 3mm deep Fig. 2 Product safety Product Safety 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 described in these instructions Laminite® Forming Procedure This practice is suitable for Chocky bars only. NOTCH 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. (Figure 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 mimimum length per weld (Figure 1) Outside Curves: Hammer down unwelded end of bar with a soft face hammer to bend bar to match mating radius. (Figure 2) Inside curves: Starting in the center strike bar with a soft face hammer to bend bar to match mating radius. (Figure 3) 3. Stitch weld as per the weld procedure. Fig.A Fig.2 Fig.1 Fig.3 10 Rubbadex® Wear Plates Remar® Wear Plates A patented acoustic wearplate that provides all the wearresistance and impact benefits of Laminite® together with effective noise suppression layer of wear resistant rubber or polymer. When medium impact and superior wear-resisting castings are required, Remar ® white iron is the solution. With the additional insurance provided by its embedded mesh, Remar has proved to be a cost-effective and outstanding method of using brittle white iron in otherwise impossible applications. Rubbadex® was developed by PAC 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 PAC's commitment to customer service. Applications • Crusher feed cones • Impact chutes • Storage and feed hoppers • Gyratory crusher feed plates Fixings • Easy to weld using mild steel • Backing plate • Bolt directly through pre-cast holes • Bolt directly using pre-attached studs Technical Specifications 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). Product Range Made to customer's requirements. Plate sizes typically up to 1.25m2 with wear plate thickness 30mm to 50mm. A range of standard Rubbadex® wear plates are available. Remar® was created by PAC in 1982. The specially coated steel mesh has been embedded in a manner somewhat analogus to reinforced concrete but with the aim simply to preserve the integrity of the casting in the event of a crack occuring in service. Long wear life combined with low risk failure are the criteria by which the true value of Remar® can be assessed. Remar® has proven durability and performance. It is backed by PAC's commitment to customer service. Applications • Autogenous mill liners • Small ball mill liners • Crusher concaves • Rod mill liners • Ore Chutes • Oscillating feeder liners Fixings • Bolt directly through pre-cast holes • Bolt directly using studs welded to embedded mesh or cast-in backing plate. Technical Specifications White iron: Modified AS2027 15/3 Cr Mo with finished hardness 650 HB min (62 Rc). Mesh: Hard-drawn low carbon steel. Product Range Cast to customer's requirements. Typically used for sections greater than 50mm thick, or where Laminite® is unsuitable. 11 DOMITE LAMINITE High Stress gouging abrasion test data Wear factor 0.9 Impact Data Typical results of non-standard IZOD impact test carried out on 16 x 10 mm un-notched specimens. Ratio of white iron/steel in laminated specimens was 3:1. Test Results 0.8 0.7 A 0.6 Material 0.5 0.4 0.3 15/3 – Cr/Mo Plain Casting, annealed 0.2 0.1 0.0 IN AM L ex I L ® CR W E® ad o DO r e bb CrM CrC yp Ru .H m La IT C Cr L SO • ASTM G81 Assessment Type Austenitic Mn steel casting White iron castings (WCI) Laminated white iron plates er W C 1* 00 6 AR C W in M t. us e St AR 45 0 * 0 50 C2 W AR Hardness Description - HB Q &T 100 19.05 240 Q &T 100 25.40 232 AR 400 AR 450 AR 500 AR 600 19.05 19.05 19.05 19.05 384 390 462 552 MnSt 19.05 205 CrMo WI 19.05 730 Hyperchrome®19.05 710 25.4 755 Laminated 19.05 Hyperchrome® 640 White iron / laminate Rubbadex CrC weld overlays CrC SOL 25.4 564 CrC DOL 25.4 595 WC 1 19.05 478 PTAW tungsten 5 AR el 00 • Wear ratio/factor (F) for each plate Thick .-mm Laminite® 3* A Type / Ident. Rolled reference steel Rolled AR steel p Hy ® CR 25.4 750 WC 2 19.05 397 WC 3 19.05 491 ASTM A 514 Grade B structural steel ASTM A 514 Grade B structural steel CMnB abrasion resistant (AR) steels. Quenched & tempered to various nominal hardness levels Solution treated ASTM A 128 Grade A ASTM A532 11B (15%Cr3%Mo3%C) Proprietary hypereutectic high Cr ASTM A532 11B (15%Cr3%Mo3%C) WCI brazed to a steel backing plate Proprietary hypereutectic high Cr WCI brazed to a steel backing plate ASTM A532 11B rubber (15%Cr3%Mo3%C) WCI bonded to a rubber /steel layer 6.4 mm thick single pass ~30%Cr 4%C bal. Fe deposit. 9.6 mm thick, double pass~30%Cr4%C bal. Fe deposit. 4 mm thick 60Wt.%, cast overlays carbide & crushed (eutectic) WC in a 50HRC nickel alloy matrix. 4 mm thick 60Wt. % macrocrystalline (monolithic) WC in a 30HRC nickel alloy matrix. 4 mm thick 60Wt.% macrocrystalline (monolithic) WC in a 50HRC nickel alloy matrix. B C 15/3 Cr/Mo 15/3 Cr/Mo Brazed to Brazed to mild steel quenched & backing tempered steel backing D SAE4150 Casting, oil quenched & tempered Vickers Hardness 406 927 927 490 Average impact – Joules 18 156 233 250 A =Results are for plain white iron casting without a backing plate. B =Results reveal that the impact properties of Laminite® 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 Laminite® impact properties by a further 50% and is comparable to a high strength chrome-moly steel in the fully heat treated condition * Independant testing carried out by Amdel Laboratories Your nearest distributor: 123 Hayward Avenue, Torrensville, SA, 5031, Australia Phone: +61 8 8416 6101 +61 8 8416 6102 Fax: +61 8 8354 0776 Email: [email protected] Website: www.dartco.com.au ISO 9001-1994 Lic No QEC2551