Hardplate™ solution improves Barmac® VSI crusher by Metso performance

Welding Alloys has developed a more reliable wear protection solution for a Barmac® VSI crusher by Metso base plate for a customer in the asphalt industry.

The asphalt producer manufactures high-performance asphalt using steel slag aggregate recovered from the steelmaking industry. Although this material supports a more sustainable approach to road construction, its density and abrasive properties create demanding wear conditions within crushing and processing equipment.

Limitations of the previous design

The rotor base plate was previously manufactured from abrasion-resistant steel and protected using welded chocky blocks and additional hardfacing patterns.

During operation, the raised sections created by the chocky blocks and weld deposits interfered with the rotating wear components. These components could catch on the uneven surface, causing the base plate to tear and deform. Over time, the plate sustained severe structural damage and could no longer provide stable or consistent protection.

The repeated failures resulted in several operational challenges for the asphalt producer, including:

• Unplanned equipment downtime
• Frequent component replacement
• Increased expenditure on replacement parts
• Reduced operational reliability

A different approach was therefore required—one that could provide complete wear protection while eliminating the raised areas responsible for the mechanical damage.

A single-piece Hardplate™ solution

Following an assessment of the application and its principal wear mechanisms, Welding Alloys redesigned the component using a single piece of Hardplate™ 100 in a 20+5 mm configuration.

Hardplate™ 100 is a composite wear plate designed to provide protection against severe abrasion and moderate impact. The 20+5 mm configuration consists of a 20 mm base plate with a 5 mm wear-resistant overlay.

Unlike the previous design, the new component provides a continuous, flat wear surface across the entire base plate. Removing the protruding chocky blocks and irregular hardfacing patterns prevents the rotating components from catching on the plate and causing structural damage.

The single-piece design also simplifies component replacement and delivers consistent protection across the entire wear area.

A reliable and repeatable solution

The redesigned base plate has successfully overcome the mechanical problems associated with the previous arrangement, providing the asphalt producer with a more dependable solution for this demanding application.

Following its successful introduction, the component has become a routinely ordered part. The asphalt producer now typically purchases two base plates on three occasions each year, demonstrating the repeatability and continued value of the solution.

By combining application expertise with the proven abrasion resistance of Hardplate™ 100, Welding Alloys has helped the asphalt producer improve equipment reliability, simplify maintenance and reduce the operational disruption associated with premature component failure.

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