Mechanical equipment needs to be protected and maintained, especially their exposed parts; otherwise, businesses would incur enormous expenses. Whether you own your business equipment or rent it, you’re aware of how essential it is to keep it in excellent condition so that it doesn’t interfere with the operations of the business. However, there is an optimal solution available for the equipment’s wear and tear problems, namely, ceramic wear plates or abrasion-resistant wear plates.
In this guide, we will delve deep into the concept and benefits of using ceramic wear plates for various industrial applications as well as how they are useful in different types of industries.
What are Ceramic Wear Plates?
Ceramic wear plate manufacturers use ceramic materials for manufacturing of wear plates such as aluminum oxide (Al2O3), zirconia (ZrO2), or silicon carbide (SiC), which are very hard, near to the hardness of diamonds, as well as resistant to wear and tear. They are designed to minimize the wear and tear on surfaces exposed to heavy machining, causing intense friction that eventually leads to damage on both sides. They are also corrosion-resistant, oxidation-resistant, and heat-resistant. They possess a hardness of 9 or 10. A robust and long-lasting wear plate is formed by joining the ceramic components together using a high-strength adhesive.
Benefits of Ceramic Wear Plates
There are various features and benefits of using ceramic wear plates in industrial applications. Some of them are mentioned here:
- Extended Equipment Life – The wear resistance property of ceramic wear plates protects the equipment from wear and tear leading to better cost efficiency.
- Improved Efficiency – The property of ceramic wear plates is to reduce wear and friction on the surface of the equipment, which helps to improve the efficiency of your business equipment.
- Cost Efficient – Ceramic wear plates help reduce downtime, operational costs, and maintenance costs. It is cheaper than replacement parts and repair costs of the equipment.
- Easy Installation – Ceramic wear plates are lightweight and can be installed easily into the system which can reduce disruption in operations.
- Reduced Noise & Vibration – Ceramic wear plates have the property to absorb noise and vibration which ultimately makes a sustainable environment for employees to work.
Properties of Ceramic Wear Plates
Ceramic wear plates have the following properties:
- Corrosion Resistant – Ceramic wear plates are highly corrosion and oxidation-resistant in nature, which offers usefulness in all kinds of weather and can withstand chemical attacks.
- Temperature Resistant – Ceramic wear plates have a high-temperature resistance feature due to low thermal conductivity, low thermal expansion, and high thermal capacitance.
- Wear Resistant – The strong chemical bond that holds them together makes the ceramic wear plates extremely hard and robust owing to their high wear resistance and protects the equipment from wear and tear.
- Tensile Strength – Ceramic wear plates are generally hard and brittle, possessing high tensile strength. However, in a high-tension scenario, it is not a suitable fit as in a tension case, the flaw or crack is free to grow due to its brittleness.
- Elastic Modulus – Ceramic wear plates are generally bonded ionically or covalently. They have stronger chemical bonding which yields higher elastic modulus in comparison to metals.
Uses of Ceramic Wear Plates
Ceramic Wear plates are used in various kinds of industries which are elaborated as follows:
- Chutes and hoppers – Ceramic wear plates are used in lining chutes as well as hoppers which protects them from wear and tear caused by abrasive materials. This helps in the reduction of maintenance costs and downtime in production.
- Conveyors – Ceramic wear plates are used to line conveyor belts to protect them from wear and tear or damage caused by abrasive materials like stones. This helps in reducing costs and extending the equipment’s life.
- Feeders and Mixers – To protect the feeders and mixers from damage caused by abrasive materials, they are lined with ceramic wear plates. Operation cost and maintenance costs are reduced making them effective in the production process.
- Pipework – Pipework is used to transport corrosive and abrasive materials. So, ceramic wear plates can be used to line pipework to protect them from corrosion and abrasion in turn extending the life expectancy of the equipment.
- Mining and Aggregate – Ceramic wear plates are used to protect the equipment of mining and aggregate by applying it on their surface from friction and tear.
- Power Generation – Ceramic wear plates are used in power generation plants using coal to protect combustion equipment and coal processors from corrosion and abrasion.
- Cement Production – In the course of cement production, ceramic wear plates are used in cement production plants in order to protect the equipment from wear and abrasion.
- Food Processing – Ceramic wear plates are non-toxic and easy to clean. They are used in food processing plants to protect the equipment from abrasion and ensure the safety of the food products.
How to Choose the Right Ceramic Wear Plate
There are quite a few things to consider while you are choosing a ceramic wear plate for your industrial needs. The category of ceramic material utilized is the first factor. The most frequently used substance is Alumina, while Silicon Carbide and Zirconia are also popular choices. The material’s abrasion resistance and hardness should align with the demands of the application. Along with the technique of installation, the wear plate’s size and shape should be taken into account. To choose the optimum wear plate for your unique application, it’s crucial to speak with an expert in ceramic solutions.
To ensure the longevity of ceramic wear plates, proper maintenance and care are essential. To check for any signs of wear or damage, regular examination should be conducted. However, if there is any damage found, the wear plate should be replaced immediately to prevent further damage to equipment. It is also essential to follow the step-by-step guidelines of the manufacturer for installation and handling to prevent any unnecessary wear or damage.
By understanding the benefits, different properties, and usage of ceramic wear plates, you can make an informed decision on whether they are the right solution for your industrial needs. With proper maintenance and care, ceramic wear plates can provide long-lasting abrasion resistance and help extend the life of your equipment.