Industry Solutions for the Ceramics and Refractory Industry
In the ceramics and refractory industry, fine-grained raw materials such as clay, chamotte, magnesite and corundum pass through presses, mills and mixers in large quantities. This fine, mineral material acts like sandpaper on every steel surface.
Augers and mouthpieces lose their dimensional accuracy, grinding rings and linings become thin, and in cyclones the flow-induced wear eats through the steel shell. This costs service life and product quality.
We supply wear protection solutions, spare parts and welding consumables that address exactly these issues and keep your components in service longer.
Typical Welding Defects on Presses, Mills and Cyclones
With fine-abrasive raw materials, the quality of the hard overlay layer determines its service life. Two damage patterns occur particularly frequently in the ceramics and refractory industry — both can be reliably avoided with the right approach.
Problem: Mineral Undercutting
If the applied layer has pores or cracks, fine-abrasive particles penetrate the transition to the base material. They undercut the layer, detach it from the component and the wear protection fails from below.
Our Solution: Homogeneous Layer with Buffer Layer
With a pore-free, homogeneous hard overlay layer, clean welding technique and a matched buffer layer, the transition remains sealed. This prevents minerals from undercutting the layer.
Problem: Spalling Due to Incorrect Layer Combination
If hardness and toughness do not match, the buffer layer is missing or heat management is incorrect, the hard top layer spalls under continuous load. The component then wears faster than without protection.
Our Solution: Matched, Multi-Layer Build-Up
High-alloy welding consumables with suitable hardness and toughness, clean preheating and slow cooling keep the layer in place. For heavily stressed components, we build it up in multiple layers.
Suitable Welding Consumables for Augers, Mills and Mixers
In the ceramics and refractory industry, the load is almost always fine-abrasive: clay, chamotte, magnesite and corundum abrade components uniformly and relentlessly. We align the welding consumable and layer build-up to the specific raw material. Against fine abrasion, we use chromium carbide-rich to complex carbide top layers, with a tough buffer layer underneath against spalling and mineral undercutting. Depending on the raw material and component, we combine the alloy systems. Via the following wear types you can reach the appropriate welding consumables for each application area.
Corrosion
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Metal-to-metal friction wear
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Impact stress
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Temperature
Show productsSpare and Wear Parts for the Ceramics and Refractory Industry
Fine-grained raw materials and high pressures cause heavy wear in mixing, grinding and pressing equipment. Here you will find suitable wear and spare parts for your equipment:
Fully Automated Overlay Welding and Additive Manufacturing
In the Laser Competence Centre, capilla brings together modern technologies for coating and component manufacturing.
Here, components are specifically treated, wear-resistant layers are applied and complex components are manufactured using additive processes such as 3D cladding.
This enables solutions that go beyond conventional welding applications and make components sustainably more capable.
Andreas Frische
Technical Management
Do you have wear problems, recurring damage or want to operate your plant more economically?
Our experts support you in selecting suitable welding consumables, in treating components and in developing long-lasting solutions.
Together we will find the approach that fits your application both technically and economically.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Why capilla
Holistic Approach
From welding consumable to finished component – all solutions work together.
Focus on Wear
Specialisation in applications with high abrasion and mechanical load.
Practice-Oriented Consultation
Analysis of real applications rather than theoretical recommendations.
Proprietary Technologies
Laser Competence Centre for coating and additive manufacturing.
capilla Wear Protection to Bulk Material Specification
We do not work with standard recipes. Whether bulk material, medium or workpiece — what matters is always the actual load acting on the component. Grain size, hardness, temperature, flow or chemical aggressiveness determine which type of wear dominates and which protection truly fits.
Before we define the welding consumable, process and layer structure, we analyse the operating conditions. This results in a solution tailored to your component. Tested consumables and defined parameters are part of this — supplemented by standards-compliant documentation for safety-critical components.
Frequently Asked Questions about Wear Protection in the Ceramics and Refractory Industry
Industry solutions for the ceramics and refractory industry include homogeneous hard overlay layers, repair welding and high-alloy welding consumables for production equipment. They are used on auger presses, extrusion presses, mixers, mills and cyclones, where fine-abrasive mineral raw materials cause particularly high wear. The goal is longer service life, less maintenance and economical upkeep of equipment in the ceramics, refractory and brick industries.
In the ceramics and refractory industry, fine abrasion from mineral raw materials such as clay, chamotte, magnesite and corundum dominates. Auger presses, extrusion presses, mixers and mills are most heavily exposed to this load, because large quantities of fine-grained material are continuously processed there. Added to this is flow-induced wear in cyclones and pipelines, where fine-abrasive particles strike the steel shell at high velocity.
Auger presses and extrusion presses are protected by homogeneous hard overlay layers on augers and mouthpieces. High-alloy welding consumables resist fine abrasion from the moist, mineral raw material and significantly extend service life. For heavily stressed mouthpieces in the brick industry, the hard overlay is placed specifically at the exit zones to permanently ensure dimensional accuracy and strand quality.
Mills and grinding equipment are protected by overlay welding on grinding rings, grinding bowls and linings. For fine-abrasive raw materials such as quartz sand, chamotte or corundum, carbide-rich hard overlay layers are used that withstand mineral undercutting. This keeps grinding performance and product quality stable over long service lives in the ceramics and refractory industries.
For the ceramics and refractory industry, high-alloy welding consumables designed for fine abrasion and mineral undercutting are used. Depending on the raw material and component, different alloys are employed — from chromium carbide-rich flux-cored wires to complex carbide materials for particularly fine-abrasive loads. Decisive is the combination of a hard top layer and a matched buffer layer that prevents spalling.
Mixers and mixing tools are protected by targeted hard overlay on the contact surfaces. Linings, mixing tools and shafts receive carbide-rich top layers against fine-abrasive loading from the raw material mix. This keeps mixing quality and dimensional accuracy stable over long service lives without premature component replacement.
In the brick industry, augers, mouthpieces, mixing tools and brick scrapers are particularly heavily stressed. The moist, fine-abrasive clay causes high fine abrasion on all steel conveying and pressing components. Overlay welding with high-alloy welding consumables economically restores dimensional accuracy and service life, and significantly extends the useful life of these wear parts.
Mineral undercutting occurs when fine-abrasive particles attack the transition between the applied layer and the base material. It is prevented by homogeneous hard overlay layers without pores or cracks, clean welding technique with matched parameters, and a suitable buffer layer between the base material and the hard top layer. This keeps the layer sealed even under long-duration loading and reliably protects the component.
Spalling is usually caused by incorrect layer combination, unsuitable heat management or missing buffer layer. It is prevented by high-alloy welding consumables with suitable hardness and toughness, clean preheating of the base material and slow, controlled cooling. For heavily stressed components in auger presses, mills and cyclones, multi-layer build-up is standard practice.
Overlay welding pays off in the ceramics and refractory industry wherever fine-abrasive raw materials cause predictable wear on steel components. Classic applications are augers and mouthpieces on auger presses and extrusion presses, grinding rings and grinding bowls in mills, mixing tools and linings, and the steel shells of cyclones. Targeted overlay with high-alloy welding consumables significantly extends service life and is usually more economical than component replacement.