Choosing the Right Wear Liner: Materials and Applications Explained
Mild Steel
Mild steel wear liners are typically supplied as sheets, measuring 1200 millimeters (48 inches) long, 200 millimeters (8 inches) high, and 12 millimeters (1/2 inch) thick. They are suitable for materials with very low abrasion levels or belts with light loads and low operating hours, such as sawdust, wood chips, and garbage. Mild steel wear liners are cost-effective for projects with budget constraints but requiring satisfactory short-term performance. In damp or corrosive environments, mild steel's higher corrosion rate may increase friction in the loading zone. These liners are available in straight or deflector patterns.
Abrasion-Resistant Plate
Abrasion-resistant plate wear liners (AR plates) offer significantly longer lifespans compared to mild steel. They are versatile enough to handle abrasive materials like sand, hard rock mining ores, and coal, extending wear life up to five to seven times longer than mild steel. AR plates are available in both straight and deflector styles.
Ceramic-Faced
Ceramic-faced wear liners are ideal for continuously operating belts carrying highly abrasive materials with minimal impact. They consist of a mild steel backing plate with ceramic blocks attached, primarily on the lower 100 millimeters (4 inches) of the plate. For heavier loads, ceramic blocks can be applied higher up to minimize wear. Ceramic-faced wear liners excel with materials such as coal and wood chips and are offered in straight and deflector styles.
Stainless Steel
Stainless steel wear liners offer abrasion resistance between mild steel and AR plates. They are chosen for applications requiring chemical resistance against corrosion. The coefficient of friction varies significantly between stainless steel and bulk materials, necessitating power requirement reviews for retrofitting with stainless steel liners. These liners are available in straight and deflector styles.
Chromium Carbide Overlay
Chromium carbide overlay is a highly durable material suitable for conveyors subjected to intense abrasion. It is overlaid onto a backing plate (mild or stainless steel) to enhance toughness. This material ranks between 53 and 65 Rockwell "C" hardness and is available in single-weld or double-weld pass grades, with the latter typically preferred for wear liner applications. Chromium carbide overlays are suited only for straight wear liner styles due to their brittleness under high impact.
Plastic
Plastic wear liners, such as Ultra-High Molecular Weight (UHMW) polyethylene or urethane, are relatively recent innovations. They are used for fine, dusty materials and are positioned directly on the belt with slotted holes for adjustment. UHMW liners are effective with materials like sand, fly ash, and electric-arc furnace dust, including food-grade applications approved by the U.S. FDA. Urethane liners are favored in lightweight applications such as gold mining and ore processing. Plastic wear liners are designed for straight applications only due to reduced service life in deflector designs and sensitivity to high temperatures and belt speeds.