Wear Protection for Foundry Equipment
In foundries, components are under three-fold pressure: moulding sand abrades, melts and slags attack chemically, and temperatures at moulds, dies and tooling constantly cycle between hot and cold.
Over time, tools crack, mixer blades lose their profile and liner plates in the shot-blast room wear thin. Every failure slows casting output and costs expensive tooling.
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 Moulds, Dies and Casting Tools
When repairing hot casting tools, heat management determines success or rejection. Two failure patterns occur particularly frequently; both can be safely avoided with the right approach.
Problem: Hot Cracks Due to Incorrect Temperature Management
Moulds, dies and tools operate at fluctuating high temperatures. If preheating is omitted before welding or the component cools too quickly, thermal stresses build up and the weld bead cracks hot.
Our Solution: Controlled Heat Management
We preheat, maintain a defined pass sequence and cool slowly and in a controlled manner. This keeps thermal stresses low and the weld bead crack-free.
Problem: Porosity in the Overlay Layer
Contamination on the surface or an unclean process traps gas in the weld pool. The overlay layer becomes porous and cannot withstand the stress of foundry operation.
Our Solution: Thorough Preparation and Verified Processes
With thoroughly prepared surfaces, tested heat-resistant welding consumables and documented parameters, a dense, pore-free layer is produced.
Suitable Welding Consumables for Moulds, Mixers and Shot-Blast Rooms
In the foundry, location determines the type of stress: hot and thermally cyclic at moulds and dies, highly abrasive at mixers and liner plates, chemically attacked in melt contact. We select the filler material precisely according to these requirements. Against heat and thermal cycling we use nickel- and cobalt-based alloys; against sand abrasion, chromium carbide-rich flux-cored wires. For combined stress, multilayer systems consisting of a tough buffer layer and a hard top layer are applied. 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 Foundries
Moulding sand and continuous mechanical stress cause heavy wear on components in foundries. 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 Foundries
Industry solutions for foundries include wear-resistant overlay coatings, repair welding and component-specific welding consumables for all foundry equipment. They are used in sand preparation, moulding and shot-blasting, on moulds, dies, mixers and conveying components. The goal is longer service life, less downtime and economical maintenance of heavily stressed components.
Three dominant stresses act in foundries: sand abrasion from moulding sand and reclaimed sand in sand preparation and shot-blasting, heat and cyclic temperatures at moulds, dies and tooling, and chemical attack from melts, slags and binder systems. These stresses frequently occur in combination, making the choice of layer structure and welding consumable demanding.
The greatest wear occurs at moulds, dies and casting tools due to heat and thermal cycling, in sand preparation on mixers, mixer linings, mixer blades and mixer knives due to sand abrasion, and in the shot-blast room on liner plates, wear plates and impact bodies. Material transport on screws, cylinders, pipes and pipe bends is also a source of wear.
Moulds and dies are restored by repair welding with heat-resistant and high-temperature welding consumables. Critical factors are cyclic temperatures and hot cracks, which are avoided by preheating, controlled heat management and slow cooling. This allows expensive tooling to be reconditioned multiple times rather than being replaced.
For foundry equipment, heat-resistant and wear-resistant alloys are used, matched to the specific stress. For heat and thermal cycling at moulds and dies, nickel- and cobalt-based welding consumables are used; for sand abrasion in sand preparation and shot-blasting, chromium carbide-rich flux-cored wires. For mixed stress, multilayer systems combining a tough buffer layer and a hard top layer are applied.
Sand abrasion in sand preparation and moulding is reduced by hard-facing on mixer linings, mixer blades and mixer knives. Carbide-rich top layers resist the fine-abrasive moulding sand; a tough buffer layer compensates stresses relative to the base material. This keeps mixers and conveying elements dimensionally accurate over long service intervals and the sand circuit runs without disruption.
Screws, cylinders, pipes and pipe bends in foundries are protected by targeted overlay welding with wear-resistant hard-facing layers. Where sand abrasion dominates in conveying lines, chromium carbide-rich welding consumables are used; for combined stress, a multilayer structure. This significantly extends service life compared with uncoated components.
In the shot-blast room, liner plates, wear plates and impact bodies are protected by hard-facing. The stress there is highly abrasive and impact-dominant, which is why a multilayer structure with a tough base layer and hard top layer is standard. This allows service life in shot-blast and finishing systems to be multiplied.
Hot cracks during welding on moulds, dies and tools in foundries are avoided by controlled heat management. Preheating before welding, a defined pass sequence and slow, controlled cooling reduce thermal stresses. Added to this are tested heat-resistant welding consumables that are permanently compatible with the cyclic temperatures of the foundry environment.
Repair welding on mould parts, dies and casting tools is almost always worthwhile when dimensions and functional surfaces can be specifically restored. Especially for large, expensive or lead-time-critical components, reconditioning with heat-resistant welding consumables is significantly more economical than a new component. Prerequisites are correct heat management and a welding consumable matched to heat and chemical attack.