Wear Protection Solutions for Conveying Technology
Belt conveyors, bucket elevators, screw and chain conveyors transport bulk materials around the clock. Every transfer point, every chute and every trough is a wear zone: the material rubs during conveying and strikes the steel on impact.
Worn bucket lips, eroded chutes and abraded screw flights slow material flow until the conveying line shuts down unexpectedly.
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 Conveying Equipment in Bulk Material Contact
Conveying components rarely fail due to the base material, but usually because of an incorrect protective layer. Two defects occur repeatedly in bulk material conveying technology, from spalling hard-facing to unsuitable welding strategy. Both are preventable.
Problem: Spalling Due to Incorrect Layer Combination
If a hard top layer is applied to chutes, buckets or screw flights without a load-bearing base layer, it cannot withstand the combined stress of abrasion and impact. The layer spalls off and the component wears faster than without any protection.
Our Solution: Tough Base Layer, Hard Top Layer
We build up the wear protection in multiple layers: a tough base layer absorbs impacts, while a hard, carbide-rich top layer resists abrasion from the bulk material.
Problem: Component Failure Due to Incorrect Basic Design
If the welding strategy is not matched to the bulk material, wear type and geometry of the conveying component, the component fails prematurely – for instance when the layer disrupts material flow or is subjected to the wrong type of stress.
Our Solution: Matched Welding Strategy
We specify layer structure, welding consumable and welding position precisely for the respective bulk material and dominant wear type. This keeps material flow constant and service life high.
Suitable Welding Consumables for Chutes, Bucket Elevators and Screws
In conveying technology, less depends on the individual component than on the path of the bulk material: where it slides, it abrades; where it impacts, it strikes. We select the filler material and layer structure precisely according to this stress. For pure abrasion along the conveying line, we work with carbide-rich hard-facing layers; at transfer points and feed zones, with tougher, impact-resistant alloys. When both occur together, a tough base layer supports the hard top layer. Use the following wear types to find suitable welding consumables for your specific application.
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 Conveying Technology
Conveying systems, chains, screws and deflection points are exposed to heavy abrasion. Find suitable wear and spare parts for your equipment here:
Fully Automated Overlay Welding and Additive Manufacturing
At the Laser Competence Centre, capilla brings together modern technologies for coating and component manufacturing.
Here, components are selectively tempered, 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 equipment more economically?
Our experts support you in selecting suitable welding consumables, in component tempering and in developing long-lasting solutions.
Together we find the approach that is technically and economically suited to your application.
+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 stress.
Practical Consulting
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 always matters is the actual stress acting on the component. Particle size, hardness, temperature, flow or chemical aggressivity determine which type of wear dominates and which protection truly fits.
Before we specify the welding consumable, process and layer structure, we analyse the operating conditions. This produces a solution that fits your component. Tested filler materials and defined parameters are part of it, supplemented by standards-compliant documentation for safety-critical components.
Frequently Asked Questions about Wear Protection in Conveying Technology
Industry solutions for conveying technology include wear-resistant overlay coatings, repair welding and component-specific welding consumables for all types of conveying systems. They are used on belt conveyors, bucket elevators, screw conveyors, chain conveyors, rotary valves and chutes. The goal is longer service life and reduced downtime across the entire bulk material conveying operation.
In conveying systems, wear occurs wherever bulk material meets steel: on chutes, rotary valves, in bucket elevators, on screw conveyors and in the troughs of chain conveyors. The causes are generally abrasion from the bulk material, impact wear at impingement zones and continuous material flow along the conveying line.
In bulk material conveying technology, abrasion from continuous bulk material conveying and impact wear at transfer points and impingement zones dominate. Depending on the conveying system and bulk material, mixed forms occur, for example in bucket elevators (impact during pickup, abrasion in the buckets) or in screw conveyors (sliding and abrasive wear on the screw and trough).
Chutes and rotary valves are protected by targeted overlay welding with hard top layers. For combined abrasion and impact stress, a multilayer structure is applied: a tough buffer layer supports a hard, carbide-rich top layer that resists the bulk material. This keeps material flow constant and service life significantly higher than with uncoated components.
The welding consumable for conveying technology depends on the type of stress and bulk material. Where abrasion dominates, chromium carbide-rich or complex carbide flux-cored wires are used; for impact wear, tougher alloys with a buffer layer. For mixed stress in conveying systems with bulk material contact such as bucket elevators or screw conveyors, a multilayer structure is standard.
Welding solutions for chain conveyors include overlay welding on carrying bars, drivers and trough linings as well as repair welding on worn functional surfaces. Layer structure and welding consumable are matched to the conveyed bulk material and the stress from abrasion and impact wear.
Bucket elevators are protected by hard-facing at the most heavily stressed zones, typically on bucket lips, feed zones and in the area of material entry. A tough base layer absorbs impact wear; a hard top layer resists abrasion from the conveyed bulk material.
Screw conveyors are restored by targeted overlay welding on screw flights and the trough wall. For abrasive bulk material conveying, a carbide-rich hard-facing is applied to the flights; for combined stress, a multilayer structure. This restores conveying capacity without having to replace the complete screw.
Downtime can be reduced by preventive wear protection on the critical components of conveying systems, i.e. where abrasion and impact wear occur predictably: chutes, rotary valves, buckets in bucket elevators, screw flights in screw conveyors and drivers in chain conveyors. Planned build-up within the maintenance window is generally far more cost-effective than an unplanned failure.
Typical defects are spalling due to incorrect layer combination, cracks due to uncontrolled heat management and premature component failure due to an unsuitable welding strategy on conveying systems subject to bulk material stress. They can be avoided by applying a tough base layer, a matched hard top layer, tested welding consumables and defined parameters, all specified for the respective bulk material and dominant wear type.