Carbide pad applied on the centrifugal separator

05/07/2025 admin

Why Choose Small hard alloy pad Welding Technology in Decanter Centrifuges?

Comparison of Wear-Resistant Technologies Among Major Brands

Brand	Gasket Welding	Alternative Technology	Application Areas
ANDRITZ	✅ Yes	Small tungsten carbide gaskets	Municipal, Biomass, Chemical
Flottweg	✅ Yes (some models)	Replaceable liner + welded gasket modules	Hazardous waste, Mineral processing
Alfa Laval	❌ No	Zirconia ceramic covering	Food, Marine, Mining
Westfalia	❌ No	Ceramic coating, Alloy inlay	Pharmaceuticals, Fine chemicals
Pierre Reis	❌ No	Carbide spraying + Alloy spiral	Mining, Oil drilling

Key Benefits of Small Wear-Resistant Pads

The spiral blades in decanter centrifuges are exposed to intensive abrasive wear due to continuous contact with solid particles such as:

Mineral fines
Crystalline salts
Biomass residues
Metal fragments

Welding small carbide pads to the screw conveyor blades addresses these issues effectively.

Advantages Include:

✅ Superior Abrasion Resistance: Protects against high-hardness materials in contact zones.
✅ Reduced Maintenance: Sacrificial pads absorb wear, protecting the main spiral blade.
✅ Extended Equipment Life: Delays the need for expensive part replacements.
✅ Lower Downtime: Minimizes operational interruptions due to wear-related failures.

Why Weld Multiple Small Gaskets Instead of One Large Plate?

Adapts to Complex Curved Surfaces: Easier installation on helical blade geometries.
Distributes Stress & Impact: Reduces crack risk due to thermal/mechanical stress.
Simplified Maintenance: Damaged gaskets can be selectively replaced.
Enhanced Welding Quality: Smaller weld zones improve structural integrity.
Cost-Effective Over Time: More targeted protection with reduced material waste.

Case Studies: Brands Utilizing Gasket Welding

ANDRITZ

Technology: Dense welding of small tungsten carbide gaskets (10–20 mm) on blade surfaces.
Advantages: Excellent coverage of high-wear areas, replaceable modules, strong substrate bonding.
Use Cases: Municipal sludge, biomass waste, chemical sludge.

Flottweg

Technology: Modular wear liners with welded carbide blocks or strips.
Advantages: Dual protection (liner + gasket), high replacement efficiency.
Use Cases: Hazardous industrial waste, mineral tailings.

TCC’s Contribution: Custom Casting & Welding of Carbide Gaskets

TCC Co., Ltd specializes in producing high-quality cast carbide gaskets, supporting welding services with strong material compatibility.

Materials Commonly Used:

Material	Key Feature	Typical Application
Tungsten Carbide (WC-Co)	Ultra-hard, durable	Mineral wear, solids processing
Chromium Carbide (Cr₃C₂)	Corrosion-resistant	Chemical and biomass slurry
NiCr-Si-B Alloys	Weldability, thermal match	Stainless steel blades, uniform stress
Cermet	Thermal shock resistance	High-temp drying, crystallization

Advantages of Cast VS Machined Gaskets

Complex Shapes in One Step: Cast gaskets fit curved surfaces more naturally.
Material Gradient Design: Can embed cores with different thermal/mechanical properties.
Scalable Cost: Casting becomes economical for high-volume, high-alloy content parts.

Welding Methods and Process Control

Common Welding Techniques:

Brazing: For low-stress or smaller parts; uses Ni or Ag-based filler.
Plasma Arc / Laser Welding: Precision, low distortion, ideal for thin blades.
Surfacing + Composite Welding: For enhanced impact and wear performance.

Process Control Tips:

Preheat and slow cooling to reduce cracking risk.
Maintain strong fusion and proper weld penetration.
Use staggered multi-point welding to minimize distortion.

Industry Trends

📌 Standardized modular gasket systems are gaining popularity.
🤖 Asian manufacturers have adopted automated gasket welding machines.
🔍 Smart monitoring systems now provide wear tracking and replacement recommendations.

Conclusion

The welding of small wear-resistant carbide pads onto decanter centrifuge spiral blades is a technically efficient, cost-effective, and scalable solution for industries facing harsh abrasive environments. TCC offers robust capabilities in casting, material matching, and welding—making it a reliable partner in extending the life and performance of high-value rotating equipment.

The method of welding for the defects of Aluminum alloy parts

01/07/2025 admin

Which welding is the better option for the defects of Aluminum alloy parts , argon arc welding (TIG/MIG), laser welding or cold welding ?

Think about the logic for selection ,

Deformation-sensitive parts (such as machined products): cold welding → laser welding → argon arc welding
High-strength parts : laser welding → argon arc welding → cold welding
Thick and large parts/low-cost repair : TIG welding → Laser welding (high power)

These are based on a detailed comparison of the core differences, characteristics and welding deformation of argon arc welding (TIG/MIG), laser welding and cold welding . The further specific analysis is as below :

1. Basic principles and core differences,

Method	Principle	Heat input characteristics
TIG welding	The base metal and welding wire are melted by electric arc (non-melting electrode TIG/melting electrode MIG), and argon gas is used to protect the molten pool from oxidation.	High heat input and wide heat affected zone.
Laser welding	The high-energy laser beam melts the metal instantly, and the argon/helium gas is used for protection, which is a high-energy density fusion welding.	Concentrated heat input and narrow heat affected zone.
Cold welding	High-pressure plastic deformation (solid-state welding) or micro-arc discharge (micro-melting) achieves atomic-level bonding with virtually no heat generation.	Very low/no heat input , no heat affected zone.

2.The Comparison of heat affected zone width,

3. The Comparison of core features,

Characteristic	TIG/MIG welding	Laser welding	Cold welding
Heat input	High, wide heat affected zone (prone to grain coarsening)	Concentrated, narrow heat-affected zone (about 1/3 of argon arc welding)	Virtually no heat input , no heat affected zone
Welding speed	Slow (TIG) to medium (MIG)	Very fast (up to 10m/min)	Slow (spot welding/repair)
Melt Depth	Medium-deep (current dependent)	Deep and precisely controllable (high aspect ratio)	Very shallow (surface binding only)
Oxidation Control	Depends on the purity of argon gas. Aluminum alloy needs AC TIG to break the oxide film	Requires high-purity protective gas, sensitive to oxide film	No oxidation problems (normal temperature operation)
Joint strength	Close to the parent material (need high-quality welding wire and process)	≥ Parent material (deep melting welding with high density)	≤ Parent material (joining surface is the pressing area)
Applicable thickness	Thin-Thick (0.5mm~25mm+)	Thin-medium thick (0.2mm~12mm, high power up to 20mm)	Ultra-thin (≤2mm, repairing micro defects)
Equipment cost	Low (TIG) / Medium (MIG)	Very high (laser + precision motion system)	Low-Medium (Press/Micro-arc Equipment)
Technical Difficulty	Medium (TIG requires skilled workers, MIG is easy to automate)	High (needs precise parameter adjustment, centering, and protection)	Low (simple operation, mainly pressure control)
Typical Applications	Structural parts, containers, special-shaped welds	Precision parts, battery housings, aerospace parts	Precision repair (pores, scratches), electronic components, heat-sensitive parts

4. The Comparison of deformation after welding,

Method	Deformation Source	Deformation degree	Control Difficulty
TIG welding	High heat input → severe thermal expansion and contraction , large residual stress, thin parts are prone to warping and corner deformation	★★★★★ (maximum)	Thin plate deformation is difficult to control, requiring strong fixture + anti-deformation design
Laser welding	Heat input is concentrated, but aluminum alloy conducts heat quickly → local shrinkage stress is still significant (especially in long welds)	★★★☆☆ (Medium)	Parameter optimization can reduce deformation, but it is difficult to completely eliminate it
Cold welding	No thermal stress , only micro plastic deformation caused by pressure	★☆☆☆☆ (very small)	Almost no macro deformation, suitable for high-precision parts repair

5.The key points of Deformation control,

Argon arc welding : requires pre-setting of anti-deformation, segmented skip welding, and water-cooling tooling, and correction is often required after welding.
Laser welding : Pulse welding, high scanning speed, and optimized path can reduce deformation, but fixtures are still required.
Cold welding : uniform pressure is sufficient, close to “zero deformation” , and no secondary processing is required after repair.

6. Suggestions,

Pursuing zero deformation → cold welding
▶ Applicable scenarios: repair of precision instrument parts, thin-walled parts (≤2mm), heat-treated parts, electronic housings.
▶ Limitations: low strength requirements (≤80% of parent material), limited to small area repairs.
Balance strength and deformation → Laser welding
▶ Applicable scenarios: aerospace parts, sealed housings, battery welding (deep melting requirements), automated production lines.
▶ Key: High equipment investment, suitable for mass production.
Cost priority, accept controllable deformation → TIG welding
▶ Applicable scenarios: large structural parts, thick plates (>5mm), non-standard single-piece production.
▶ Skills: TIG is used for high-quality welds, MIG improves efficiency; the surface of the welding material needs to be strictly cleaned.

Conclusion,

Dimensions	TIG welding	Laser welding	Cold welding
Heat input	high	Medium-High (Concentrated)	none
Deformation	great	medium	Very small
strength	High (close to base material)	Very high (deep melting and dense)	Medium-Low
cost	Low	Very high	middle
Best Scenes	Thick plates, structural parts	Precision parts, deep melting requirements	Ultra-thin parts, zero deformation repair

The influence of material properties on welding repair selection

The different materials of aluminum alloy have significant differences in adaptability to welding repair methods due to differences in alloying elements, heat treatment characteristics, etc.,

Material Category	Feature	Optimal welding method
6xxx series ( Al-Mg-Si )	Heat treatment strengthened type, difficult to restore mechanical properties after welding	Laser welding / cold welding (low heat input)
5xxx series (Al-Mg )	Non-heat treatment strengthening, stable performance after welding	High suitability for MIG/ cold welding
2xxx series (Al-Cu )	High crack sensitivity, difficult welding	Laser welding requires preheating + post-heating
7xxx series (Al-Zn-Mg )	High strength, easy to soften	Cold welding is suitable for small area repairs, laser welding should be used with caution

Post-weld heat treatment/correction needs assessment

The impact of different welding methods on subsequent processes is as follows,

Welding method	Need heat treatment after welding?	Need Shaping calibration?	Precautions
TIG welding	T6 state is required , reheat treatment is recommended	Need (especially thin parts )	Easy to warp
Laser welding	Small thermal impact, generally no need	May need	High automation precision but high equipment cost
Cold welding	No	No	Fine repair is suitable, and structural parts are used with caution

WHICH PROCESS IS THE MOST COST-EFFECTIVE FOR SMALL PARTS, MIM ,COLD HEADING AND COLD EXTRUDING?

22/07/2023 editor

WHAT’S THE DIFFERENCE ON MIM , COLD HEAD AND COLD EXTRUDING?

Which process is the most cost-effective for those small parts less than 50g, MIM , cold heading or cold extruding?

The cold heading process which is a branch of cold extrusion is most right way to manufacture the bolts, screws, nuts, nails, pins and other standard fasteners.

During the process of manufacturing bolts, the forming of the hexagonal head is made by cold heading, and the reduction of the rod part is cold extruding(extrusion). The non-cut hexagonal flange bolts (multi-station forming) are done by both cold heading and cold extruding, the hexagonal nut has only be done by cold heading before forming, and the extruding hole in the post process by cold extruding (positive and negative extrusion).

Cold heading process is a kind of processing method by the plastic deformation of the metal under the action of external force, and with the help of the mold, the volume of the metal is redistributed and transferred, so as to form the required parts or blanks.

At present, cold extrusion technology has been widely used in fasteners, machinery, instruments, electrical appliances, light industry, aerospace, shipbuilding, military and other industrial sectors, and has gradually become the development direction of small and medium-sized forgings refined production.

Cold extruding is the process by the metal blank in the cold extrusion cavity, at room temperature, through the press fixed punch to apply pressure to the blank, the metal blank produce plastic deformation and the processing method of parts. Cold extrusion is one of the machining processes of parts with no chips and less chips.

Cold extrusion is also divided into positive extrusion, reverse extrusion, composite extrusion, radial extrusion and so on.

MIM (Metal Powder Injection Molding Technology), The injection molding process can directly form thin-wall and complex structural parts, and the shape of the product is close to the requirements of the final product, and the dimensional tolerance of the parts is generally maintained at about ±0.1-±0.3. In particular, it is of great significance to reduce the processing cost of cemented carbide, which is difficult to be machined, and to reduce the processing loss of precious metals.

MIM is suitable for mass production of parts. Due to the use of injection machine molding product blank, greatly improve the production efficiency and reduce the production cost.

MIM has wide range of applicable materials and application field (iron base, low alloy, high speed steel, stainless steel, hard alloy).

If you have some small parts and not sure which is the best way to manufacture , please feel free to contact Alina@tcc-casting

Iron oxide desulfurizer

22/05/2022 editor

adsorbent to clean associated petroleum gas from hydrogen sulfide

EN1.4405 , Small Parts , Investment Casting Or Metal Injection Molding(MIM)?

02/04/2022 editor

The most cost-effective for the small metal parts which are less than 50g.

For some small metal parts which are less than 50gram, they used to be casted directly in the past. Since there is another process called metal injection molding which is focusing on the small parts in recently years, which process is the most cost effective way?

Mostly the MIM is more suitable than the investment casting, however, It still need to be analyzed case by case.

Let’s take the wear segment like above image as an example.

The weight is 36 Grams.

The structure of this part is simple.

The dispatch condition is blank casting or raw part.

The tolerance is referred to VDG-Sheet P690 D1

The annual quantity for this part is around 30,000/ year.

According to this information, It is concluded that the investment casting is most cost- effective process to manufacture this part. For the molding cost of this part , metal injection molding(MIM) is three times than the investment casting.For the unit cost of this part, Metal injection molding is 2.5 times than the investment casting.

The advantages of metal injection molding compare to investment casting are follows.

The High working efficient .
No machining or less machining
Better tolerance and surface requirement.
Complicated structure.

So you can see none of these advantages are applied on this part .

If you have some small parts to OEMs, let’s discuss case by case and we will give you the best solution. Please send email to alina@tcc-casting.com

Aviation casting

23/03/2022 editor

Aerospace Investment Castings

When aeronautical engineers design aircraft ,considering the safe, perform well, and can be built and sold at a competitive price, for certain parts with unusual or complicated shapes it is often by casting with appropriate heat treating and machining rather than forging .Investment casting is more economically and technically feasible on aerospace industry.Parts ranging from high to low complexity which are made from durable and corrosion resistant materials are possible. TCC understand the quality and precision that the industry demands which enable us to provide a wide range of investment cast parts for applications in both commercial and military aerospace sectors.

At TCC, we have a proven track record of producing some investment cast parts for aerospace applications that meet strict industry standards , eg bracket for J-10CE. Some of our capabilities in this sector are as follow:

In depth knowledge in working with a vast number of standard and super alloys such as stainless steel, PH stainless steels (17-4 ), carbon steel, and Nickel based super alloys like Inconel 718, Inconel 625, and alluminum alloy.
Use of the latest 3D modeling (SolidWorks) and solidification analysis (Pro-Cast) software’s.
In house rapid prototyping technologies with the ability to print 3D waxes.
When necessary we can design and implement soluble and ceramic cores into our tooling and workflow.

With a high level of casting expertise, stringent process control and certified quality systems of AS9001, we proudly provide reliable and cost-effective aerospace investment castings for the following applications:

Valves
Mounts
Swirl Nozzles
Engine Blades
Engine Rings
Vanes
Engine Impellers
Aircraft fluid management systems
Interior components
Hydraulic fluid system components

Quality is always the top priority at TCC. Certifications and compliances we adhere to for the aerospace industry is EN ISO 9001:2015 and EN9100:2018 .

For more details , please contact us with email : alina@tcc-casting.com

Flare tips in Combustion Industry turn-key supply

08/03/202223/03/2022 editor

turn-key supply

Experience achieved flare and power burner parts for combustion system OEMs in the Oil & Gas industry, TCC now has not only manufacture the spare parts and the tube ,but the flare tips design and assemble , such as the spare and replacement of gas tips, flame stabilizers (cones or diffusers), ignition components, burner pilot parts . All components in the heat-affected zone are made from 310 stainless steel (HK) material and some others are made of AISI304 .

Our gas tips are engineered and manufactured to strict tolerances to meet client’s equipment functions pOur gas tips are engineered and manufactured with strict tolerances to meet client’s equipment functions properly. Our cones, flame stabilizers, and pressure block devices are cast or manufactured from high-grade materials to ensure long life and performance.TCC can supply a wide variety of investment cast or fabricated cones / flame holders / diffusers for round or flat flame burners.

TCC is a design and manufacturing company focused upon providing superior quality in the combustion assemble to a wide range of industries including oil & gas production, petrochemical, refining, bio-gas waste disposal, and industrial manufacturing,our customer includes Zeeco , Encore and CNPC .

Boiler Casting Spare Parts &Combustion Casting Accessories

02/10/202102/10/2021 editor

Investment casting for boiler accessories and combustion parts

The commonly casting material for boiler accessories and combustion parts is heat-resistant steel, the widely used is HH, HK, A-27 GR60-30 and CL1/ G17CrMO5-5. The common casting methods are silica sol investment casting and sand casting. For the investment casting , The weight can be casted from 0.01g to 120kg with the tolerance CT5 to CT7 and the surface roughness from Ra 3.2 to 12.5. For the sand casting , The weight can be casted from 5kg to 2500kg with the tolerance CT11 to CT13 and the surface roughness from Ra 25 to 50.

Technic	Material	Weight	Tolerance	Roughness
Silica sol investment casting	HH,HK,A-27 GR60-30, CL1/G17CrMo5-5	0.01-120KG	CT5-CT7	Ra3.2-12.5
Sand casting	HH,HK,A-27 GR60-30, CL1/G17CrMo5-5	5-2500KG	CT11-CT13	Ra25-50

The Common boiler accessories are hood, such as double hole arrow hood, porous cap, grille hood, “7” type hood, and support block, sliding block, male and female buckle, grate hanging plate, pipe clamp, anti-wearing tile and so on

TCC is experienced in manufacturing the boiler accessories and combustion parts .If you have any inquiry , our technician are happy to discuss with you , please feel free to contact email alina@tcc-casting.com

EN 1.4308 (GX5CrNi19-10) Stainless Steel

08/08/202108/08/2021 editor

GX5CrNi19-10 (EN 1.4308) is same stainless steel material as SS304, EN 10213: 2007 Steel castings for pressure purposes EN 10283: 2010 Corrosion resistant steel castings ISO 11972:2015 specifies cast steels for general corrosion-resistant applications.X5CrNi18-10 (EN 1.4301) is the similar grade in standard of in EN 10088-3

GX5CrNi19-10 (EN 1.4308) similar grade:

American: ASTM A351 CF8 (J92600)

American: ASTM A743 CF8 (J92600)

American: ASTM A744 CF8 (J92600)

American: ASTM A297 CF8 (J92600)

Japanese: JIS 5151 SCS13

Chinese: GB/T 12230 ZG0Cr18Ni9

France: AFNOR Z6CN18.10M; Z6CN19.9M

UK: BS3100-4 304C15

Korea: KS D4103 SCS13

Germany: DIN 17445 GX6CrNi18-9

Heat treatment process: Solution annealing + water quenching (+AT)

Heat to 1050-1150°C for sufficient time to heat casting uniformly to temperature and water quench

GX5CrNi19-10 (EN 1.4308) BENEFITS

Corrosion and pitting resistance Better for abrasive applications

Higher strength than standard stainless steel Improved ductility and weldability

Better resistance to embrittlement

GX5CrNi19-10 (EN 1.4308)APPLICATION

it’s the most popular stainless steel used in such Pump industry, Machinery spare part ,Automobile industry , Food industry…

The challenge for this part is keeping the teeth of the two juicer parts perfectly meshed when putting the fruit inside to squeeze.

If you have some parts which could be machining directly or cast , let’s discuss what kind of technic is most fit for you . TCC’s technician could design the drawing for you according to your idea , or propose the most suitable technic for you . Contact TCC casting .

What’s The Difference Between Aluminum Gravity and Pressure Die Casting?

01/08/202103/08/2021 editor

Gravity Die Casting VS Pressure Die Casting

There are two main processes which is gravity die casting and pressure die casting for Aluminum alloy .

What is the Gravity Die Casting?

Gravity Die Casting ( called Permanent Mold Casting in USA and Canada)is a permanent mold casting process , where the molten metal is poured from a vessel or ladle into the mold. The mold cavity fills with no force other than gravity, filling can be controlled by tilting the die. Undercuts, and cavities can be incorporated into the component form with the use of sand cores.

It specifically refers to metal casting, however, sand casting, metal casting, investment casting, lost mold casting can also be included generally .

Advantages of Gravity Die casting

-Less pores and can be heat treated.
-Low density
-Product finish is not high.
-Low production efficiency.
-Molding with long lifetime and low cost
-Simple technic process
-Not suitable for parts with thinner wall.

What is the Pressure Die Casting?

Pressure Die casting includes high pressure casting and low pressure casting.

Low-pressure die casting is a method of production that uses pressure – rather than gravity – to fill molds with molten metal such as aluminum and magnesium. In this process, the holding furnace is located below the cast and the liquid metal is forced upwards through a riser tube and into the cavity. The pressure is applied constantly, sometimes in increasing increments, to fill the mold and hold the metal in place within the die until it solidifies. Once the cast has solidified, the pressure is released and any residual liquid in the tube or cavity flows back into the holding furnace for “recycling.” When cooled, the cast is simply removed.

Advantages of Low-Pressure Die Casting

-Precise control of the filling process.
-Reduces oxide formation and porosity.
-Ensure superior consistency of the partsfrom top to bottom
-Exceptional density , strength values and excellent dimensional accuracy.
-Fit for parts with simpler, symmetrical forms, complex geometries
-Uncomplicated machinery and technology, well to automation.

High-Pressure Die Casting (HPDC) is an extremely efficient manufacturing method for producing various product forms. The process forces molten metal at high speed, and high pressure into a closed steel die cavity. The die has a stationary and moving half, both of which are mounted to the die casting machine’s platens. The die casting machine has an injection end that uses hydraulics and pressurized gas to move a piston forward, injecting the molten metal into the closed steel die. The die casting machine also has a clamping end that utilizes hydraulics and mechanical toggles to absorb the injection pressure and hold the die shut while the part solidifies. The process is capable of turning molten metal into a solid near-net-shape part in seconds.

Advantages of High-Pressure Die Casting

-Fast filling, high production efficiency.
-High compactness, high product strength and surface hardness, low elongation.
-Good surface finish, generally up to RA6.3 or even Ra1.6.
-Fit for Products with thin wall thickness (the thinnest to 0.5mm).
-Much gases in Internal , poor porosity .
-Not allow heat treatment, small machining allowance (better less than 0.25mm ).
-High cost and short time life for molding

Comparison For Gravity die casting, High- pressure and Low- pressure

How and Which Die casting to choose, Gravity , High-pressure or Low-pressure die casting?

It mainly according to the wall thickness of the product:
As the high production efficiency ,the high- pressure die casting should be preferred priority if the production process and product performance can be met.
When the wall thickness of the product is over than 8mm, the high-pressure die-casting can not meet the expected requirement due to too many internal pores, the gravity die casting and low- pressure die casting can be considered.Generally ,low pressure casting is a compromise between high pressure casting and gravity casting.

TCC provide a complete manufacturing service solution for each project and application.For more information on Aluminum Gravity and Pressure Die Casting, please feel free to contact alina@tcc-casting.com.