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CERAMIC INFUSED SHAFT SLEEVES

TOUGH TECHNOLOGY FOR TOUGH CONDITIONS

The Slurrytech CIS shaft sleeve is an exciting new technology wear coating that offers amazing robustness and wear life unmatched by existing technology and products.

The CIS product offers a uniformed particle matrix able to withstand thermal cycling without the catastrophic delaminating problems normally associated with spray coatings, CIS performance far exceeds HVOF, PTA, Laser & others coatings.

Utilising revolutionary spray technology in the coating process our sleeves avoid many of the problems associated with conventional ‘thermal spray’ processes offering the following advantages:

  • High density, uniformed carbide microstructure.

  • Major reduction of inclusions, porosity and oxidisation.
     

  • Near metallurgical bond strength.
     

  • Thermal cycle stability.
     

  • Reduced residual stresses.
     

  • Retained properties of initial particles.
     

  • High corrosion resistance to leaching and pitting.
     

  • High hardness with excellent wear resistance.
     

  • Excellent mechanical strength.
     

  • Resists delamination through material hardness and property disassociation.


COMMON SLEEVE FAILURE MODES

Fatigue Fracture.

A common failure mode for coated shaft sleeves is Fatigue Fracturing. Fatigue fracturing occurs when a material is put under a repeat load cycle such as rotary movement with a high radial load creating a flexing effect and or torsional load.

In most weld coatings parent material of the sleeve is undercut to facilitate the weld / thermal inlay. This results in a metallurgical bond of a harder, high carbide matrix to a ductile substrate. In service torsional and radial loads are applied to the sleeve, the substrate with lower hardness and higher toughness can generally withstand these forces. The harder weld inlay however always has a lower fracture toughness along with inherent stress causing fatiguing and fractures in a spiral type tortoise shell pattern that depicts the loads being applied in service.

Traditional spray coatings such as HVOF suffers a similar fate as the harder coating is fractured and compromised.

The image below shows a typical failure mode for PTA shaft sleeve that is becoming more prevalent within the industry.

Matrix Failure.

Matrix failure occurs when a sleeves suffers from “wash out” which can happen long before they wear out. The binding matrix that holds the harder wearing carbides in place is washed away by either chemical attack or by submicron wear. This leaves the sleeve with a "fluffy" abrasive surface of exposed carbides which attack the packing materials.

Manufacturing Faults.

In an independently commissioned report on one of the most widely used sleeves it was discovered that the wear resisting carbides were simply not bound sufficiently in the matrix, in simple terms they were falling out like loose teeth. The root cause for this result is based in manufacturing control of heat / energy input along with shielding gas control which can compromise the matrix integrity.
 

COATING PROPERTIES

The following table gives an overview of different coating technologies and their properties.
 

 Properties

SlurrytechTM
CIS
Thermal
Spray HVOF
Weld
Overlay PTA
Plasma
Spray
 Bond Strength
 High
 Very Low
 Very High
 Low
 Complex Geometries
 No
 No
 Difficult
 No
 Abrasion Resistance
 High
 Moderate
 High
 Moderate
 Erosion Resistance
 Good
 Low to Moderate
 Moderate
 Low
 Corrosion Resistance
 High
 Low
 Moderate
 Low
 Impact Resistance
 Moderate
 Low
 Moderate
 Low
 Oxide Level / Porosity
 Very Low / Very Low
 High
 Low / Low
 High
 Temperature Resistance
 Moderate to High
 Moderate
 Moderate
 Moderate
 WC % Concentration
 ~ 85
 ~ 65 - 70
 ~ 65 - 75
 ~ 60
 Metallurgical Bond
 Infused Bond
 No
 Yes
 No
 Life Factor
 1.8 - 4
 1.0
 1.5 – 2.5
 0.8 - 1.0

MATRIX FEATURES

The micrographs below show CIS, PTA and HVOF matrix structures.

PTA and HVOF coatings have clearly defined phases of material between hard phase (Carbides) and the binder along with some matrix flaws of porosity and oxidization.

The CIS coating however presents a uniformed matrix with fewer flaws and a more uniformed microstructure.

CASE HISTORIES

CIS sleeves have been proven successful in some of the most arduous duty conditions.

High thermal cycling frequency which normally causes coatings to fracture and/or delaminate has minimal effect on the CIS sleeve.

Refinery Transfer

Pump: 8/6E-AH

Sleeve Run Hours Wear mm Location / Failure Conclusion
PTA 960 4.0 Uniformed across sleeve / Fractured Replace
Laser 960 3.0 Uniformed across sleeve / Washout Replace
CIS 1000 1.0 - 1.5 Localised at lip seal / Reuse Reverse after another 1000hrs

Cost Impact: 1 cycle = 1000hrs

CIS sleeve =  1 sleeve x 1.4 cost / 1 cycle life = Cost Factor = 1.4

PTA sleeve = 2.5 sleeve x 1.0 cost / 1 cycle life = Cost Factor = 2.5

Conclusion: CIS Sleeve has higher initial cost but is more almost twice as cost effective as PTA and other materials.


Gold Tailings

Pump: 6/4E-AH

Sleeve Run Hours Wear mm Location / Failure Conclusion
PTA 2500 3.0 Localised gouging / Early fracture pattern Replace
HVOF 1120 ? Uniformed ? / Delaminated coating Replace
CIS 2360 0.4 Uniformed across sleeve / Reuse Reuse x 4

Cost Impact: 1 cycle = 9440hrs

CIS sleeve =  1 sleeve x 1.4 cost / 1 cycle life = Cost Factor = 1.4

HVOF sleeve = 4 sleeves x 1.0 cost / 1 cycle life = Cost Factor = 4.0

Conclusion: CIS Sleeve has higher initial cost but is more almost 3 times as cost effective as PTA and other materials.


Mineral Sands

Pump: 4/3D-AH

Sleeve Run Hours Wear mm Location / Failure Conclusion
PTA 500 1.5 Localised gouging / Fracture pattern & packing Replace
HVOF 400 ?  ? / Delaminated coating & packing Replace
Laser 600 0.8 Uniformed / Slight fracturing Reuse?
CIS 1120 0.5 Uniformed across sleeve / Reuse Reuse x 2

Cost Impact: 1 cycle = 2000hrs

CIS sleeve =  1 sleeve x 1.4 cost / 1 cycle life = Cost Factor = 1.4

Laser sleeve = 2.5 sleeves x 1.0 cost / 1 cycle life = Cost Factor = 2.5

Conclusion: CIS Sleeve has higher initial cost but is more almost twice as cost effective as Laser and other materials.


Please feel free to contact us and arrange to trial this exciting technology improvement in your slurry and solids handling pumps.

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SLURRYTECH
  ®
is a registered trademark of Slurry Technology Group Pty Ltd
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All registered names, trademarks, copyrights and part numbers remain the property or their respective owners. All use of OEM names, part, model and item numbers are for reference and identification purposes only.

SLURRYTECH® is a registered Trade Mark of Slurry Technology Group Pty Ltd. WARMAN® is a registered Trade Mark of Weir Minerals. AES® is a registered trademark of AES Seals

SLURRYTECH® products are not sponsored, endorsed or approved by Weir Minerals. Slurrytech are not an endorsed reseller or representative of Weir Minerals or their respective products.

SLURRYTECH® products do not infringe on Trade Marks Act 1995 or Copyright Act 1968, and to the best of our knowledge and through investigation we are not in contravention of any current patents.