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Description of the case
For this application, Real Steel worked on site with their customer, Sollys Contractors, that provides transport, construction and earthmoving services, and was looking for a solution for their rotor discs that wore out quickly. Working together with Real Steel's wear engineers, they designed a laminated disc made from Hardox 500 and Hardox 550.
The result: total wear life of the rotor increased by three times and production costs were reduced by 30 percent.
Previously the rotor discs were hardfaced which was time consuming and expensive. The uneven wear on the rotor discs required that they be removed frequently and re-hardfaced and balanced. Frequent hardfacing led to fatigue and cracks in the base metal.
"Our solution extended the wear life while removing the hardfacing and need for re-balancing the rotors" said Luke Mathieson, Managing Director, Real Steel. "The solution also created even wear on the rotors"
Real Steel also redesigned the base plate of the rotor upgrading it from AR400 to Hardox 550. In addition a recess was machined into the disc to allow for Hardox 600 wear plate to be inserted where the main wear occurred.
Case details
Key success factors
Easier installation (weight, welding, etc.): No hardfacing and balancing required throughout service life
Improved design: New part designed with a replaceable HX600 insert where the most wear occurs.
Improved service life: Parts last three times longer
Increased crack resistance: Higher quality Hardox steel and no hardfacing required
Lower initial cost: 30 percent cheaper to produce
Lower lifetime costs: Parts last three times longer and require less downtime and cheaper repairs
New service life: 300 hours before needing minor repair work
New solution
Hardox® 600,
: 10mm HX600 + 32mm HX550 (Laminated)
Old solution
AR 400: 40mm + hard facing
