Industry solutions for wastewater technology
In treatment plants and wastewater facilities, components such as pumps, conveyor screws, agitators and scraper systems work under constant load. Moisture, abrasive solids, corrosive media and aggressive gases such as hydrogen sulphide strain the components every day.
The result is abrasion from sand and solids, corrosion from chemicals and moisture, as well as cavitation and erosion on pumps and flow-loaded components. Wear leads to declining throughput and, in the worst case, to unplanned plant shutdown.
We supply wear-protection solutions, spare parts and welding consumables that act exactly where needed and keep your components in service for longer.
Typical welding defects and how we avoid them
Durable repair in wastewater technology only succeeds with the right process control. Two defect patterns occur particularly often, both of which can be reliably avoided with the right approach.
Problem: spalling of the wear layer
An unsuitable layer combination or poor bonding to the base material causes the protective layer to spall under abrasive and impact loads. The component is then worn faster than before.
Our solution: matched layer structure
A tough buffer layer compensates for stresses towards the base material, a hard top layer resists abrasion. This keeps the layer permanently bonded even under alternating loads.
Problem: cracks from incorrect heat control
If a component is heated unevenly or cools too quickly, microstructure and residual stresses change. Particularly with cast iron and higher-alloy materials, as frequently found in wastewater technology, the weld then becomes prone to cracking.
Our solution: controlled heat control
With preheating and matched welding parameters, we keep residual stresses low and reduce the risk of cracking, matched to the respective base material.
Suitable welding consumables for pumps, conveyor screws and agitators
Wear protection in wastewater technology only works if it suits the component. We select wear protection, welding process and filler metal according to the application, depending on the medium, load and type of wear. Against aggressive media such as sewage sludge, acids and salts we use corrosion-resistant deposits, against abrasion from sand and gravel wear-resistant alloys. If both loads act simultaneously, we combine the properties in a matched layer solution. Use the following types of wear to find the right welding consumables for the respective application.
Spare and wear parts for wastewater technology
Our portfolio ranges from pumps and impellers through conveyor screws and screw presses to agitators and scraper systems. Added to this are decanters, pump housings as well as pipelines and valves. Here you will find suitable wear and spare parts for your systems:
Fully automated surfacing welding and additive manufacturing
At the Laser Competence Centre, capilla bundles modern technologies for coating and component manufacturing.
Here, components are specifically heat-treated, wear-resistant layers are applied and complex components are manufactured using additive processes such as 3D cladding.
This enables solutions that go beyond classic welding applications and make components sustainably more capable.
Andreas Frische
Technical Management
Do you have wear problems, recurring damage, or would you like to operate your systems more economically?
Our experts support you in selecting suitable welding consumables, in the heat treatment of components and in developing durable solutions.
Together we find the approach that suits your application 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 the filler metal to the finished component – all solutions interlock.
Focus on wear
Specialisation in applications with high abrasion and mechanical load.
Practical consulting
Analysis of real applications instead of theoretical recommendations.
In-house 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. Particle size, hardness, temperature, flow or chemical aggressiveness determine which type of wear dominates and which protection really fits.
Before we define the welding consumable, process and layer structure, we analyse the operating conditions. This results in a solution that suits your component. Tested filler metals and defined parameters are part of this, supplemented by standard-compliant documentation for safety-critical components.
Frequently asked questions about wear protection in wastewater technology
Screw presses, decanters, pump housings, impellers, conveyor screws, agitators as well as pipelines and valves can be repaired. Worn material is built up with wear-resistant welding consumables and subsequently reworked mechanically. capilla repairs damaged and worn components by welding instead of replacing them completely.
Depending on the component and task, we work with MIG, MAG and TIG as well as laser-powder and laser-wire surfacing welding. Hardfacing and armouring apply wear-resistant layers precisely where abrasion and corrosion act most strongly. capilla selects the process to match the base material, component and operating conditions.
In surfacing welding, a wear-resistant layer is applied to a component to extend its service life. This is worthwhile wherever components wear through abrasion, corrosion or cavitation, for example on pump impellers, conveyor screws and pipelines. capilla uses surfacing welding specifically for wear protection in wastewater technology.
In treatment plants, abrasion from sand and solids, corrosion from moisture and chemicals, cavitation on pumps, erosion from high flow velocities and impact wear act on the components. With the right layer structure these loads can be specifically absorbed. capilla matches the wear protection to the respective load collective of the component.
Against corrosion from aggressive media, nickel- and cobalt-based alloys are used that remain resistant even with sewage sludge and acids. Against abrasion from sand and gravel, iron-based hardfacing deposits are used. For combined loads a multi-layer build-up is applied: a corrosion-resistant buffer layer carries the load, a hard top layer resists abrasion. capilla composes the alloy to match the medium and load.
Conveyor screws are repaired by targeted hardfacing on the screw flights and trough wall. Worn material is built up with wear-resistant welding consumables and subsequently reworked mechanically. This restores the throughput without replacing the complete screw. capilla repairs conveyor screws precisely where wear is most severe.
Yes, pumps, impellers and pump housings can often be repaired by welding and subsequent mechanical processing. A tough buffer layer compensates for stresses towards the base material, a hard top layer resists abrasion from sand and sewage sludge. capilla repairs pump components with corrosion- and abrasion-resistant alloys.
Structural steel, stainless steel, duplex, cast iron and wear steels are processed. Welding consumable and heat control are matched to the respective base material so that the layer holds and no cracks form. capilla selects the process and filler metal to match the material of the component.
Yes, many repairs can be carried out directly on site to reduce downtimes. Especially in treatment plants, where outages are critical, on-site service enables repair within existing maintenance windows. capilla offers an on-site service for the repair of loaded components.
A repair is worthwhile wherever components are large, expensive or hard to source, for example on pumps, conveyor screws, decanters and agitators. Targeted hardfacing significantly extends the service life and is usually more economical than replacing a component. capilla checks for your component whether a repair makes technical and economic sense.