Wear Protection Solutions for the Glass Industry
In the glass industry, three stresses act simultaneously: quartz sand abrades during batch preparation and in conveying lines, molten glass and batch materials attack chemically, and temperatures at melting tanks, moulds and rollers fluctuate constantly.
Over time, functional coatings crack on hot moulds, deflection pots are washed out by cullet content, and dosing screws lose their conveying capacity. Every failure interrupts continuous glass production.
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 Hot Glass and Conveying Components
Whether on hot moulds or abrasive conveying lines, a build-up layer only holds with proper adhesion and controlled heat management. Two failure patterns occur particularly frequently in the glass industry; both can be safely avoided with the right approach.
Problem: Spalling Due to Poor Adhesion
If the base material is not properly prepared or the layer is applied with incorrect parameters, adhesion is poor. On hot glass components such as rollers and moulds, the functional coating then spalls off under thermal cycling.
Our Solution: Thorough Preparation and Matched Parameters
With thoroughly prepared base material and welding parameters matched to the component, the layer adheres permanently and withstands hot glass contact.
Problem: Cracking Due to Uncontrolled Heat Management
Moulds, rollers and contact surfaces experience constant thermal cycling. If heat is not controlled during welding, stresses build up and the layer cracks during subsequent hot-cold cycles.
Our Solution: Controlled Heat Management and Suitable Alloy
Controlled preheating, matched cooling and a crack-resistant alloy with high fail-safe properties keep the layer stable even under frequent thermal cycling.
Suitable Welding Consumables for Moulds, Rollers and Batch Preparation
In the glass industry, the zone determines the type of stress: hot and chemically attacked in glass contact, highly abrasive from quartz sand and cullet in preparation and conveying. We select the filler material precisely according to these requirements. For hot glass contact we use heat-resistant nickel and tungsten alloys with high fail-safe properties; against quartz sand abrasion we use chromium carbide-rich welding consumables. 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
Show products
Metal-to-metal friction wear
Show products
Impact stress
Show products
Temperature
Show productsSpare and Wear Parts for the Glass Industry
In batch preparation, cullet recycling and the hot glass zone, components such as moulds and rollers, mixer linings and dosing screws, or pipes, pipe bends and deflection pots are subject to especially heavy wear. We protect them with hard-facing and restore them. 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 the Glass Industry
Industry solutions for the glass industry include wear-resistant overlay coatings, repair welding and component-specific welding consumables for the entire glass production process. They are used in batch preparation, cullet recycling and on hot glass components such as rollers, moulds and contact surfaces. The goal is longer service life for components exposed to high temperatures, chemical attack and quartz sand abrasion.
Three types of stress dominate in glass production: quartz sand abrasion in batch preparation and on conveying lines, high temperatures with constant thermal cycling on melting tanks, moulds and rollers, and chemical attack from molten glass and batch constituents. A high cullet content from cullet recycling additionally intensifies abrasive stress on pipes, pipe bends and deflection pots.
Pipes, pipe bends and deflection pots in the glass industry wear particularly heavily because the conveyed batch contains a high proportion of quartz sand and cullet. This mixture acts extremely abrasively, especially at deflection points where flow direction and impact energy converge. Protection is provided by carbide-rich hard-facing layers applied precisely to the most heavily stressed inner surfaces.
Wear in batch preparation is reduced by hard-facing on mixing and comminution tools. Mixer linings, mixer blades, scrapers and dosing screws receive carbide-rich top layers against quartz sand abrasion, with a tough buffer layer added for combined impact stress. This keeps mixing quality and conveying capacity stable over long service intervals.
For the glass industry, chromium-based, nickel-based and tungsten-containing alloys are used, matched to the type of stress and temperature range. For hot glass contact on moulds and rollers, heat-resistant nickel and tungsten alloys are used; for quartz sand abrasion in batch preparation and cullet recycling, chromium carbide-rich welding consumables. Decisive factors are high fail-safe properties and low susceptibility to cracking despite frequent thermal cycling.
Moulds and rollers in hot glass contact are protected by functional layers that withstand high temperatures, thermal cycling and chemical attack. Nickel- and tungsten-based overlay welding alloys with high fail-safe properties are used. Layer thickness and alloy composition are specified for the individual component and its contact time with the molten glass.
In cullet recycling, hard-facing layers reduce wear on cullet crushers, crusher rolls and conveying components. The sharp-edged cullet acts strongly abrasively and with dominant impact, which is why a multilayer structure of tough buffer layer and carbide-rich top layer is standard. This allows service life on crushers and conveying systems to be significantly extended.
In conveying systems and conveying lines of the glass industry, screws, dosing screws, pipes and pipe bends as well as deflection pots and hopper and silo linings are especially susceptible to wear. The cause is the highly abrasive mixture of quartz sand and cullet in ongoing glass production. These components can be protected by targeted hard-facing or restored by repair welding.
Spalling is mostly caused by poor adhesion of the overlay layer; cracks by uncontrolled heat management during thermal cycling. Both defects can be avoided by thorough preparation of the base material, matched welding parameters, controlled preheating and slow cooling. For components subject to heavy thermal cycling such as moulds and rollers, correct alloy selection additionally reduces susceptibility to cracking.
Overlay welding is worthwhile in the glass industry wherever components wear predictably due to quartz sand abrasion, hot glass contact or cullet. Classic applications are melting tank components, rollers, moulds, contact surfaces, mixing and comminution tools, and conveying lines with high cullet content. Targeted build-up significantly extends service life and is usually more economical than a new component, especially for large or lead-time-critical components.