Wear Protection: Strategies for resistant Components

Where metal meets metal, extreme forces are at work. Friction, heat, and pressure put a strain on technical components during continuous operation, leading to wear. Whether in energy production, mechanical engineering, or the process industry, targeted protection is essential. Without targeted, robust protection technology, failures, costly repairs, and high expenses are imminent. Anyone who wants to protect components must understand how wear occurs—and how materials and protection methods can be intelligently tailored to address it.

What is wear?

Wear refers to the gradual loss of material on a solid surface, caused by mechanical, thermal, or chemical influences during movement between two contact surfaces. The consequences? Reduced performance, costly failures, and unplanned, expensive downtime. In industrial applications, such wear can have serious consequences. When pumps fail, turbine parts rust, or valves jam, both the plant’s performance and the overall safety of employees suffer. Therefore, effective wear protection plays a key role in product development and the operation of technical systems.

Whether in energy generation, mechanical engineering, or the process industry: protection and repair go hand in hand. This is precisely where Deloro comes in. With years of experience in materials engineering and customized manufacturing technology, we ensure that relevant components last longer, function reliably, and production processes run smoothly.

Understanding Wear: Mechanisms and Impacting Factors

Wear has many faces – and these vary depending on the application, material, and environmental conditions. In practice, several stresses often act on a component simultaneously. To select the appropriate protective measure, it is necessary to understand the type of wear.

Fundamentally, it is important to understand that (metallic) surfaces do not lie flat in reality. They are always (more or less) irregularly shaped surfaces. In a tribological system, these surfaces are also in motion and are usually subjected to pressure/force.

Tribological system in schematic diagram

Legend:
1 = Counterbody
2 = Base body
3 = Intermediate medium

The five most common types of wear are abrasion, adhesion, surface distress, tribo-oxidation, and cavitation.

Abrasion describes the loss of material due to hard particles or rough contact surfaces. The resulting wear can vary greatly depending on the abrasion resistance of the material and the lubrication.

Surface fatigueresults from cyclical stresses, such as pressure fluctuations or vibrations. It leads to cracking within the base material and promotes spalling.

Adhesion arises from friction between two surfaces, for example, when metal surfaces move against each other under pressure. Microscopic material transfer can lead to chipping, micro-welding, and irreparable damage, especially if unsuitable material pairings are used.

Tribo-oxidation occurs when friction and temperature stimulate chemical reactions. This process forms oxide layers that can provide protection but are also susceptible to wear. Careful material selection is essential to address this interaction, especially in high-temperature applications.

Cavitation occurs when local pressure drops develop in liquids, causing vapor bubbles to form and subsequently implode. The resulting micro-jets and shock waves attack the surface of a component at specific points, causing material loss through erosion. Components in pumps, turbines, or valves, which are exposed to high flow velocities and fluctuating pressure conditions, are particularly vulnerable.

No One-size-fits-all solution: Wear protection must be individually tailored

In practice, these types of wear rarely occur in isolation. Often, several factors act on a component simultaneously. This is precisely where the challenge lies in developing effective wear protection: The material properties must be coordinated to withstand multiple stresses at once. Particularly stressed surfaces in pumps, turbines, or valves are exposed to typical stressors such as mechanical stress, corrosion, or high temperatures. The choice of material and manufacturing method therefore always depends on the specific application.

Diagnosis first: The right wear protection begins with root cause analysis

To ensure that plant components have a long service life and failures are avoided, it is essential to understand the type of wear that is occurring. Only when the mechanism is understood can the appropriate protective measure be selected – such as a hardfacing coating, a cast component, forged material, or a powder metallurgy component.

Deloro Alloys: Materials for Demanding Operating Conditions

Where temperatures rise and friction increases, many materials quickly reach their limits. In such environments, the right alloy determines whether a component withstands the conditions or fails. Deloro develops alloys specifically designed for these extreme environments: resistant to wear, heat, and corrosion, reliable in continuous operation, and safe in critical applications.

Our alloys are based on nickel, cobalt, and chromium and retain their stability even at temperatures up to 1000 °C. This ensures that components remain functional, even when conditions become harsh.

A brief overview of the substantial alloy families:

The classic alloy for extreme conditions: Stellite® alloys combine high wear resistance with reliable corrosion resistance – wherever heat and stress know no respite.

For permanently hot and dry environments: Tribaloy® alloys withstand temperatures up to 1000 °C and, thanks to chromium and molybdenum, build up a dense oxide layer. They are frequently used in turbochargers, aerospace seals, and pumps.

When corrosion is the decisive enemy, Nistelle® alloys demonstrate their strengths. They resist pitting, crevice corrosion, and stress cracking – even in chloride-containing and acidic media, typical scenarios in the oil and gas or chemical industries.

Deloro® alloys from the NiCrBSi system offer wear-resistant protection up to approximately 315 °C. Their hardness is achieved through boride and silicide phases. Various variants are available, ranging from 20 to 60 HRC, including the particularly resistant Deloro 60.

For applications where abrasion is the primary concern, Delcrome® iron-based alloys offer robust solutions. In corrosion-intensive environments – such as in the marine sector – the corrosion-resistant variants are used.

For the biomedical dental sector, Deloro manufactures ISO 13485 certified Co- and Ni-based alloys – an alternative to gold and platinum, optimized for biocompatibility, corrosion resistance and the mechanical requirements of crowns and bridges.

Selection of an adequate Material

Choosing the right material is crucial for the service life and performance of technical components. Every industrial process has its own unique requirements – whether in terms of hardness, corrosion resistance, or temperature stability. Therefore, every material selection begins with a thorough analysis of the stresses and environmental conditions under which the component will be used.

Deloro offers a wide range of metallic materials covering diverse applications. These include the aforementioned cobalt-based alloys such as Stellite® and Tribaloy®, as well as nickel- and iron-based alloys. Among them are specialized solutions for extreme temperatures and pressures. The selection always depends on the dominant type of wear: For abrasive loads, alloys with a high carbide content are particularly suitable, while for adhesive wear, tough alloy systems are used.

A major advantage of cobalt-based alloys is their resistance to both mechanical and thermal stresses. Even at temperatures around 1,000 degrees Celsius, they retain their hardness and the stability of their microstructure. This makes them the ideal solution for the most demanding applications.

But it’s not just the material that counts, but also the processing method.

The Processing Method Influences the Protective Effect

The technique used to apply a material to the base material has a significant impact on the quality of the protective layer. Whether hardfacing, PTA welding, or laser cladding: a dense metallurgical bond and precisely adjusted layer thickness are crucial. Only in this way can a protective layer be created that is optimally tailored to the specific requirements. Controlled mixing, i.e., the targeted addition of base material to the protective layer, is also important – as it significantly influences the quality of the bond.

Whether solid material or coating – the appropriate solution is determined by the actual stress and operating conditions.

Use of Solid Material

Solid material is always used when the entire component is subjected to high loads across its entire cross-section. The properties of the alloy are then available throughout the component – a robust solution for extreme abrasion, pressure, or temperature stresses. Deloro manufactures such solid material components using casting, powder metallurgy, or forging processes and tailors them specifically to the respective application.

Use of Coating Measures

Coatings offer advantages when only defined areas of a component are exposed to high wear loads. Here, cost-effective base materials can be combined with highly wear-resistant surfaces. This is economical, material-efficient, and increases service life without having to manufacture the entire component from expensive high-performance material.

From consultation to solution: Deloro engineering that makes systems last longer

At Deloro, material selection doesn’t end with choosing a specific material. We provide process-neutral consulting to find the economically and technically optimal solution for your application. Using state-of-the-art manufacturing processes, in-depth analyses, and continuous process optimization, we tailor each solution to your individual needs. Technical requirements and economic objectives are considered, as well as industry-specific framework conditions. This results in components that withstand even extreme loads and sustainably improve the service life of entire systems.

Effective Wear Protection from Deloro

Wear and tear cannot be completely avoided, but it can be significantly reduced through targeted measures. The key is choosing the right process to optimize a component’s properties so that it can withstand the specific stresses it will be subjected to. Methods such as weld overlay, hardfacing, thermal coating processes, and casting are key.

Coating, Protecting, Reinforcing: Technologies for Wear-Critical Components

In industrial environments, coatings primarily serve one purpose: to provide dedicated protection. From metallurgical bonding and precise PTA processes to thermal spraying technologies such as HVOF or plasma spraying, each method has its strengths and offers opportunities to make components more durable, resistant, and cost-effective. This chapter provides a concise overview of the most important processes and their applications.

When it comes to reliable, customized surface protection, weld overlay is one of the most important techniques. In this process, a resistant layer is selectively applied to the base material, protecting it from abrasion, friction, and corrosion. Flux-cored wire and electrodes are frequently used, as they ensure a uniform material feed and thus consistent layer quality.

PTA welding is particularly efficient, allowing for precise control of the layer thickness. This enables the long-lasting protection of even heavily stressed surfaces of turbine components or valves. Suitable filler materials are available for every application, optimally matched to the specific load.

Welding isn’t the only reliable protection against wear. Thermal spraying processes like HVOF (High Velocity Oxide Fuel) or plasma spraying have also proven effective in practice. They enable the application of particularly dense and adhesive coatings that effectively withstand abrasion and corrosion. Another coating process is arc spraying. Here, suitable filler materials are melted using an electric arc, finely atomized, and evenly applied to the surface. The result is homogeneous coatings with high adhesion. Such coatings are ideally suited for components exposed to strong pressure and temperature fluctuations.

Primary Forming and Modern Manufacturing: From Casting to Additive Manufacturing

From precision casting processes and metallic 3D printing to high-density HIP components, Deloro offers a variety of methods for precisely designing components to meet their specific load requirements. Each approach has its own strengths – whether maximum density, complex geometries, or robust solid material solutions.

Casting is always the right choice when a component has to withstand extreme stresses over the long term. Deloro relies on precision casting processes such as investment casting or vacuum investment casting, which enable the creation of complex geometries and high-quality surfaces. The finished products consist entirely of wear-resistant cobalt-, nickel-, or iron-based alloys and retain their stability even at high temperatures or under heavy load cycles. Solid material components are less susceptible to surface damage, can be reworked if necessary, and recycled at the end of their life cycle – an advantage for both operational reliability and the circular economy.

From Croning Casting to vacuum investment casting, Deloro offers the right casting process for every application and desired wear protection solution.

Additive manufacturing opens up virtually endless possibilities in the production of specific components for wear protection – especially when parts require complex geometries, individual adaptations, or lightweight construction. Deloro primarily utilizes metallic 3D printing for critical components that are difficult to manufacture using conventional methods or are needed in small quantities. Cobalt-chromium-based powders are characterized by high wear, corrosion, and temperature resistance, enabling the production of components that can withstand even the most demanding applications. Thanks to Deloro’s rigorous quality assurance, printed components achieve the same material and functional quality as those manufactured using conventional methods.

Hot isostatic pressing (HIP) completely compresses metallic components under high temperature and uniform gas pressure. This process produces extremely homogeneous and pore-free materials – ideal for safety-critical applications in aerospace, energy, medical technology, and oil and gas. HIP is suitable for the post-densification of cast, additively manufactured, or powder metallurgy parts, as well as for the production of bimetallic components via so-called “HIP cladding” when welding or casting does not deliver sufficient quality, the geometries are too complex, or conventional manufacturing processes become uneconomical. Deloro offers specially developed HIP powders for this purpose, including those for demanding applications such as nuclear technology.

Consulting. Analysis. Manufacturing: The Deloro Approach

Consultation

Deloro’s consulting services come into play wherever metallic components are exposed to high mechanical, thermal or chemical stresses.

Analysis of current state

With over 115 years of combined application experience, our experts analyze the causes of wear and evaluate plant components, processes, and operating conditions. Factors such as temperature, corrosion, and load profiles are systematically recorded and form the basis for well-informed decisions.

Feasibility

Based on this, Deloro compares different material and manufacturing options in feasibility studies – always with a view to service life, process reliability and total cost of ownership.

Realization

Building on this foundation, Deloro compares various material and manufacturing options in feasibility studies – always with a focus on service life, process reliability, and total cost of ownership. The interdisciplinary engineering team combines materials, process, and application engineering to create customized, industrially viable wear protection concepts – precisely tailored to the specific application.

Manufacturing and Machining

Thanks to 100% vertical integration, recommended solutions can be implemented directly: from prototypes and pilot production runs to cast and additively manufactured components, as well as coatings and assemblies. Our own modern laboratories provide support with material, microstructure, and hardness analyses, as well as coating evaluations.

Analytical. Proven. Effective: The Deloro project workflow

At Deloro, a successful wear protection project follows a clear, proven process. This process incorporates the following:

Over 115 years of experience,
in-depth knowledge of materials and
practical analytical skills

The process usually begins on-site: Our experts analyze the relevant component, the operating conditions, or the existing (potential) wear pattern directly at the plant. The information gathered is then supplemented by Deloro’s many years of experience and targeted investigations to precisely classify the actual wear mechanism.

Temperature, pressure, movements, and contact partners are systematically recorded. In damage analysis, we use internal methods such as metallography, optical microscopy, spectral analysis, or hardness testing – supplemented, if necessary, by external hot hardness or SEM analyses.

Based on the wear mechanism, up to three suitable alloy variants are proposed. Stellite, Tribaloy, or nickel-based alloys are typical. These cover a broad spectrum of mixed wear mechanisms. This is important because in practice, only one type of wear ever occurs.

The selected candidates are tested directly in the field. This qualification cycle is a core component of our “Deloro methodology.” The initial feedback reveals which solution performs best in real-world operation.

After the final selection, we manufacture the component – depending on the requirements, as a coating, a solid material solution, or a hybrid. Thanks to our high level of vertical integration (casting, PTA, laser cladding, HIP, additive manufacturing), we can implement the complete solution in-house. Everything from a single source.

After commissioning, we continue to monitor the component in real-world use. Service life data, operational behavior, and application feedback are incorporated into a joint evaluation. This ensures that the chosen solution performs optimally in the long term – and allows us to use the insights gained to design future projects even more precisely.

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