Case StudyNovember 23rd, 2021
Duaplate® DX Weld Overlay
Pilbara Region, WA, Australia
Chute: Lower Section of Surge Bin
Bradken has engineered a revolutionary weld overlay material that provides superior wear performance and impact resistance. Unlike traditional chromium carbide overlays, our proprietary weld chemistry creates an incredibly fine microstructure which results in substantial performance improvements when compared to existing products.
Bradken’s Duaplate DX was trialed in the lower section of a surge bin, installed in an iron ore mine in Western Australia’s Pilbara region. The bin was compared to an identical chute lined with Duaplate D80.
The DX chute was lined with 8mm overlay, whilst the D80 chute was lined with 9mm of overlay. The chutes were in service for 6 months and processed comparable material and tonnages. At the end of the 6-month trial period, the bins were removed from service and thickness testing was conducted to compare wear and impact performance between the two overlay materials.
Thickness testing data showed that similar locations were prone to high wear on both bins, however the DX material showed significantly less wear compared to the D80 material. In particular two areas were worn past the D80 overlay and through the mild steel fabrication. In the corresponding locations on the DX chute, there was still a minimum of 4mm of overlay, or 50% of the wear life remaining.
Duaplate DX site trials showed that:
Bradken’s new Duaplate DX has 2.5 times longer wear life than Duaplate D80
8mm of Duaplate DX is equivalent to 20mm of Duaplate D80 in terms of service life
50% reduction in liner mass; giving a significant reduction in manual handling risks, therefore improving safety concerns