Sugar Cane Shredder
Industry: Sugar Cane Production - after harvesting, the cane sugar is transported to the mill where the cane billets are reduced by the shredder machines into fibrous materials. Then the sugar juice is removed by the extraction station.
Problem: During the smashing, shredder hammers are subject to severe abrasion as a result of the dry fibrous materials extracted from the cane sugar. Usually the shredder machine hammers are manufactured from Ni-Hard cast iron and could be designed with removable tips. Once the harvesting period begins, the shredder cannot be stopped for maintenance, emphasising the requirement for the equipment to be reliable during the whole season.
Service Conditions:
- Ambient temperature ~20°C to 50°C.
- Medium corrosion environment.
- High rotating speed, risk of medium shocks.
Caution: Usually, the shredder machine hammers are manufactured from Ni-Hard cast iron. Due to the low thermal expansion coefficient, the Ni-Hard cast Iron cannot be directly brazed thanks to the TufCote®. Intermediate removable supports (such as patches) are manufactured and then brazed with the TufCote®. After brazing the support are fitted back on the shredder.
Coating Solution: TufCote® Abrasion-Resistant Coating: Tungsten carbide with a metal matrix; 5 mm thickness. Use specifically the TufCote® Grade A 8mm ⌀ (even 6.35mm).
Benefits of the TufCote®:
- TufCote® brazing alloy extends the life time 3 times more than Ni-Hard cast iron.
- The extension of the life-time allows to make 2 campaigns (could be extended to 3 campaigns).
- Due to the fact that, TufCote® is brazed on removable patches, the hard facing operation of the shredder is an unlimited renewable operation.
- Simplicity, easy learning of the brazing procedure make it a possible application on site or in job shop.
- TufCote® can be applied on construction steel (the hard steels, or special and expensive steels are not required). Cutters could be made from relatively cheap steels
- No capital investment is required to apply the TufCote® brazing flexible cord (only a flame torch is required).
- TufCote® can be applied on construction steel (the hard steels, or special and expensive steels are not required) = shredder patches could be made from basic steels.
- Possibility to rebuilt on a coating previously welded.
- Coarse and angular tungsten carbide grains, for better resistance to abrasion (TufCote® Grade A).
- A metal wire is inserted inside the cord and avoids "butt".
TufCote® GRADE A Product Specification
- Self Fluxing Alloy Matrix: 37 to 40% in weight.
- Tungsten Carbides: 60 to 63% in weight .
- Particle Size: Grade A within 0.1 to 1.6mm (10–150 mesh).
- Packaging: TufCote® is supplied as a continuous flexible cord, length depending on diameter and included in a protective plastic box. Available in 4.75mm or 6.35mm or 8mm ⌀.
TufCote® Application Procedure
Preparation of the Piece
- Surface must be cleaned and free of surface contamination.
- All edges must be cut by grinding.
Preheating of the Area
- With oxy-acetylene torch, preheat the piece area to 450°C (840°F).
Prime Cote (if required)
When welding stainless steel with TufCote®, an under layer might be applied about 300µm thick on surface before apply TufCote®:
- To avoid any oxidation of surface
- To prevent chromium migration to the surface (black bulk)
- To increase TufCote® bonding.
Hard-facing Operation with TufCote®
- The torch flame must form an angle of about 45° with the piece surface to be hard-faced, and TufCote® at a 45° angle to the same surface.
- The flame must swing from side to side of the weld deposit.
- TufCote® is then fed through the holder 4-6” at a time.
- The tip of the cord should not be lowered or lifted during the fusion process.
- The maximum speed of deposition is about 2Kg/hour (4.2 lbs/hour).
For more information on Metal Spray equipment or consumables, call us on 07 3823 1004, or email us using our contact form.