Mechanical wear is a common issue in nearly all industrial production processes, often leading to equipment downtime for maintenance. As a primary cause of equipment breakdowns, failures, and decommissioning, wear manifests in various forms. These wear patterns frequently coexist with corrosion, high-temperature exposure, and oxidation. So what types of wear exist? How do we select appropriate surface treatment solutions based on different wear characteristics? In this series, we'll provide detailed explanations on optimal approaches for addressing various wear scenarios.
The types of wear are as follows:
Wear form | classify | Factors affecting wear |
Running-in Wear | Normal Wear | Break-in Phase Stable Wear Stage Severe Wear Stage |
Adhesive Wear | Mild Wear Smearing Wear Scuffing Wear Shearing Wear Seizure Wear | Material Characteristics Pressure Sliding Velocity Surface Finish Quality Temperature |
Abrasion Wear | Chiseling Type High Stress crushing type Low Stress Abrasion | Hardness of Metal Materials Hardness of Abrasive The Size of Abrasive Particles Metal Cooling Hardening and Impact Conditions |
Surface Fatigue | Non-extensible Extended | Material Quality Surface Hardness |
Corrosive Wear | Oxidation wear Abrasion of special media Micro-wear gas etching | Surface Finishment lubricating Surface material characteristics |
From above, there are many types of wear, and each type of wear has different causes and ways. When we choose surface treatment, it is difficult to achieve the best solution if we do not know the type of wear.
For example ：
Tungsten carbide is an exceptional wear-resistant material, making it a preferred choice for wear-resistant coatings in abrasive applications. However, there are specific limitations to its effectiveness. When dealing with high-stress crushing abrasion, tungsten carbide may not be the optimal solution. Particularly when working with hard abrasive particles or larger abrasive sizes, tungsten carbide coatings prove inadequate. While tungsten carbide coatings can indeed extend product lifespan, they are not the most cost-effective option when compared to overall expenses. For instance, a mining company approached us seeking tungsten carbide spraying for wear resistance. Rather than pushing the product based on profit motives, we recommended nickel-based blended with tungsten carbide PTA welding as the superior solution, always prioritizing what truly benefits our customers.