Wear-resistant products can be a valuable asset for businesses in various industries. These products can help extend critical equipment’s life and improve the bottom line from hospitals to food production facilities.
There are many benefits of using wear-resistant products, but selecting the right product for the application is important. In some cases, traditional materials like steel or aluminum might be more suitable. However, in other cases, a specialized wear-resistant coating might be necessary.
Various superior wear-resistance products are available on the market, but not all are created equal. To find the best product for your specific needs, it is important to understand the different types and how they can benefit your business. This go over what everything your business needs to know about wear-resistant products.
What Are Wear-Resistant Products
Wear-resistant products are designed to withstand abrasion, impact, and corrosion. They are often used in applications where high levels of wear and tear are expected, such as in the mining and construction industries.
Wear-resistant products can be made from various materials, including metals, ceramics, polymers, and composites.
The specific material used depends on the requirements of the application. For example, metals may be chosen for their strength and durability, while ceramics may be selected to resist high temperatures. Polymers and composites are often used in applications where weight is a concern, such as in the aerospace industry.
In addition to their wear-resistant properties, these materials also have other desirable characteristics, such as low friction and electrical insulation. As a result, they are used in various products, from cutting tools to electronic components.
Why Wear-Resistant Products Are Important
We rely on products that can withstand wear and tear in our everyday lives.
From the wheels on our cars to the soles of our shoes, wear-resistant materials are essential for keeping us safe and mobile. But what exactly are wear-resistant materials, and why are they so important?
Wear-resistant materials resist abrasion or wear away of a surface due to friction. Common wear-resistant materials include metals like steel and titanium and synthetic polymers like nylon and Kevlar. These materials are used in various applications, from industrial machinery to military equipment.
Wear-resistant materials are important because of their ability to prolong the lifespan of products and protect against costly repairs.
In industries like mining and construction, wear-resistant products can help protect against equipment downtime and injuries.
For example, a pair of shoes made with wear-resistant materials are likely to last longer and need less frequent repairs than a pair made with less durable materials. And in the military, wear-resistant materials can mean the difference between life and death.
How to Prevent Abrasive Wear
Abrasive wear is the loss of material from a solid surface due to friction from another solid.
It can occur when two surfaces are in sliding or rolling contact and when a hard particle is forced against a surface.
Abrasive wear can be a major problem in engineering applications, as it can lead to component failure and downtime.
To reduce the risk of abrasive wear, it is important to select hard and wear-resistant materials. In addition, proper lubrication and maintenance can help extend components’ life.
By understanding and managing the risks of abrasive wear, engineers can help to ensure the longevity and reliability of their designs.
Common Uses of Wear-Resistant Products
Wear-resistant products are essential for businesses in these industries to protect against wear and tear. Wear-resistant products are used in a variety of industries and applications.
Some of the most common uses of these products include:
Abrasive Blasting
Abrasive blasting is a widely used process for cleaning, finishing, and preparing surfaces. The abrasive materials used in the process can vary depending on the application. For example, you may use softer materials to clean delicate surfaces, while harder materials can remove stubborn contaminants. Abrasive blasting is also commonly used to prepare surfaces for painting or other finishes.
Cement Production
Wear-resistant products are commonly used in cement production. Cement is made by heating limestone and other minerals to create a powdery substance mixed with water to create a slurry.
Various wear-resistant products protect equipment from demanding conditions during the cement-making process. For example, wear-resistant linings are often used in rotary kilns to protect them from high temperatures and abrasive material.
Coal Mining
The coal mining process involves extracting coal from underground seams, which can be hazardous to workers.
To protect workers from potential injuries, many coal mines use wear-resistant products. These products are designed to withstand the extreme conditions of a coal mine, including high temperatures, dust, and debris. Common wear-resistant products used in coal mining include safety glasses, gloves, and boots.
Construction
The construction industry is one of the most important markets for wear-resistant products.
Construction applications are highly demanding, and even the slightest wear can cause significant damage. As a result, companies that produce wear-resistant products have developed a wide range of products specifically for the construction industry.
Some of the most common uses for these products include floors and walls in buildings and homes; driveways and sidewalks; parking lots and roadways, bridges, and tunnels. In each application, wear-resistant products help extend the structure’s life by protecting against wear, tear, and weathering.
Food Processing
Food processing equipment is often subject to high temperatures, humidity, and cleaning chemicals, contributing to wear and tear. Wear-resistant coatings help extend the life of equipment by protecting it from these harsh conditions.
In addition, wear-resistant materials are often used on food contact surfaces to prevent contamination.
Glass Manufacturing
Glass is a notoriously brittle material, and even small amounts of wear can cause it to break or chip. As a result, glass manufacturers often use wear-resistant coatings to protect their products. These coatings help extend the glass’s life and prevent expensive damage.
Metalworking
From tools and dies to high-speed cutting, metalworking applications put a lot of wear and tear on products. That’s why many manufacturers rely on wear-resistant coatings to protect their surfaces and extend the life of their products.
Wear-resistant coatings are used in various metalworking applications, including machining, stamping, extrusion, and Casting.
Papermaking
Wear-resistant coatings help extend the life of paper by protecting it from abrasion and moisture. You can apply these products to both sides of the paper, and you can also use them to coat the papermaking machinery itself.
In addition to extending the life of the paper, wear-resistant coatings can also improve its performance. By protecting the paper from abrasion, they can help to reduce dust buildup and improve print quality. Also, by preventing moisture damage, they can help to keep papers flat and prevent curling.
Plastics Manufacturing
Plastics are often used in applications where they will be subject to wear and tear, such as the construction of pipes and tubing. To ensure that these products can withstand the rigors of use, manufacturers often add wear-resistant coatings to their surfaces. These coatings help extend the plastic’s life by protecting it from abrasion and damage.
Steelmaking
The steelmaking process involves heating iron ore in a blast furnace to create molten steel. This steel is cast into various shapes and sizes. The final product is then cooled and tempered to create a variety of different grades of steel.
Wear-resistant products are often used in this process to protect equipment from high temperatures and abrasive conditions. For example, wear-resistant coatings are applied to the interior of blast furnaces to prevent corrosion.
Many steel mills use wear-resistant materials in their rolling mills to extend the life of their equipment.
Steelmaking also involves high temperatures and intense pressures to shape and strengthen the metal. During this process, impurities and other unwanted materials are often removed from the steel. One common method of accomplishing this is through fine particle abrasion. In this technique, small particles are blasted at the surface of the steel using high-pressure air or water.
Surface Hardening
Hardening is a way of making the material more wear-resistant. It is done by changing the properties of the surface layer so that it is harder than the rest of the material. It can be done by heat treatment, using chemicals, or adding other materials to the surface.
There are many different surface hardening methods, and each has its advantages and disadvantages. Some methods, such as carburizing, are very effective but take a long time to process. Others, such as nitriding, are much faster but do not produce as much surface hardness.
The choice of method depends on the specific application and the required properties. In general, the surface hardened proves to be an effective way to extend the life of a wear-resistant product.
Case Hardening
Case hardening is a process of surface hardening in which a layer of hard material is added to the surface of a metal. This layer helps to protect the metal from wear and tear, and it can also improve the metal’s resistance to corrosion. The case hardening process usually involves adding carbon to the surface of the metal. You can do it by heating the metal in the presence of carbon-rich materials, such as charcoal or coke. The carbon diffuses into the surface of the metal, forming a layer of carbide. This carbide layer is much harder than the metal itself, and it helps protect the metal from scratches, abrasions, and other forms of wear.
Case hardening is often used to improve the durability of tools and machinery parts subject to high levels of stress and wear.
Businesses That Need Wear-Resistant Products
Businesses that need wear-resistant products often fall into one of three categories:
- Those that produce goods: manufacturers of all types of products, from automobiles to appliances. Many of these businesses require wear-resistant products to protect their products from damage during shipping or handling.
- Those that provide services: from restaurants to janitorial services. These businesses often need wear-resistant products to protect their employees from slips and falls.
- And those exposed to the elements: companies that operate in extreme environments, such as construction sites or mines. These businesses need wear-resistant products to protect their employees and equipment from the elements.
Wear Resistant Products
Premium Rubber
Premium rubber is a type of synthetic rubber that is produced through the copolymerization of butadiene and acrylonitrile. It is characterized by its high resistance to wear and tear, making it an ideal material for products subject to heavy use.
Premium rubber is also resistant to oil and chemicals, making it ideal for various industries.
In addition, premium rubber has a high degree of elasticity, which allows it to return to its original shape after being stretched or compressed. It makes it an ideal material for products that need to be flexible and durable.
Premium rubber is also resistant to heat and cold, making it an ideal material for products exposed to extreme temperatures.
Ceramic Tiles
Ceramic tiles are wear-resistant flooring made from natural clay and other minerals. It is popular for residential and commercial applications because it is durable, easy to clean, and available in various colors and styles.
Ceramic tiling can be used on walls, floors, countertops, and backsplashes. They are also impervious to water, ideal for damp areas such as bathrooms and kitchens.
It is important to consider the thickness, glaze, and tile size when choosing ceramic tiles. Thicker tiles are more durable and less likely to crack or chip, while glazed tiles are easier to clean and maintain.
Mining Hoses
One of the most critical pieces of equipment in a mine is the hose. From the moment material is first extracted from the ground until it’s transported to buyers, hoses are used to move everything from water and slurries to sludge and tailings. That’s why it’s so important to use hoses designed for durability and wear resistance.
Internal and External Protective Coatings
There are two main wear-resistant products: internal and external protective coatings.
Internal coatings are applied to the surface of an object, while external coatings are applied to the outside of an object. Both types of coatings provide effective protection against wear and tear.
Internal coatings are typically made from harder materials than external coatings. It is because they need to withstand the constant friction of moving parts. Internal coatings are often applied to bearings, gears, and other moving parts. They help extend the life of these components by reducing wear and tear.
External coatings are usually made from softer materials than internal coatings. It is because they do not need to withstand as much friction. External coatings are usually applied to non-moving parts, such as pipes and walls. They help protect these surfaces from deterioration caused by exposure to the elements or other factors.
Final Thoughts on Wear Resistance Products
The industrial market is growing, and with it, the demand for wear-resistant products.
Wear-resistant coatings can protect your equipment from abrasion and corrosion. There are a variety of coatings to choose from that will meet your specific needs. Prepare your business now with wear-resistant products to avoid downtime and increased costs in the future.
Wear-resistant products are important for any business as they help maintain the appearance and function of equipment.
There are a few wear-resistant products that businesses should be aware of. Each type has its benefits that can be helpful for certain industries.
Businesses should contact an industrial coatings specialist to find the best wear-resistant product for their needs. The specialist will be able to provide information on the different types of coatings available and determine which is best for the company’s specific situation.
About Atlas Wear Solutions
Atlas Wear Solutions (formerly Atlas Rubber and Ceramic Tiling) have been servicing Australia-wide for over 20 years. We specialize in providing industrial rubber and ceramic linings as well as wear and corrosion protective coatings. We have a fully equipped workshop in Oak Flats and can provide onsite work with our equipment that including mobile compressors, blast hopper units, and generators with fully trained and highly qualified & experienced staff.
We offer a large range of premium rubber, ceramic tiles, mining hoses, and internal and external protective coatings, giving you, the client, much more choices of products and services at very competitive prices.
We are committed to finding the best solution for your abrasion and wear problems with our dedicated team of application technicians.
Useful Terminology
Thermal Expansion Coefficient
The thermal expansion coefficient measures how a material expands in response to heat.
It is usually expressed as a linear coefficient, which is directly proportional to the temperature change.
A thermal expansion coefficient is a negative number for many materials, indicating that the material contracts when heated. However, the thermal expansion coefficient is positive for some materials, such as water, meaning that the material expands when heated. The value of the thermal expansion coefficient can be used to calculate the change in dimensions of a material in response to a temperature change. In addition, you can use it to predict how a material will respond to thermal stresses. It is an important property for engineers to consider when designing products or structures.
Coating Hardness
Coating hardness measures a coating’s ability to resist indentation, scratching, and abrasion.
The hardness of a coating is determined by its chemical composition, cure state, and microstructure. Harder coatings are typically more wear-resistant and durable than softer ones. However, they can also be more brittle and susceptible to chipping and cracking. The hardness of a coating can be measured using various methods, including the pencil test, the Rockwell hardness test, and the Vickers hardness test.
Composite Materials
A composite material is a material made from two or more different materials combined to create a new material with improved properties. The most common type of composite material is fiber-reinforced plastic, which is created by combining a plastic matrix with reinforcement fibers.
This combination of materials results in a stronger and lighter material than the original materials. Composite materials are used in various applications, including aerospace, automotive, and construction.
Mechanical Properties
Mechanical properties are the properties of a material that reveal its elastic and inelastic behavior when force is applied, which means its ability to deform elastically or plastically.
The most important mechanical properties are strength, flexibility, high hardness, brittleness, and fracture toughness. These properties depend primarily on the type of bonding between atoms in a material and secondarily on the direction of layering or crystalline orientation.