Vacuum Brazed Tungsten Carbide Wear Solution
Vacuum Brazed
Tungsten Carbide Wear Solution
Engineered Wear Protection for Severe Abrasion & Impact
IntegriMat provides custom vacuum brazed tungsten carbide wear solutions for components operating under severe abrasion, erosion and impact conditions.
By combining the exceptional wear resistance of cemented tungsten carbide (WC-Co) with the structural strength of an engineered steel substrate, we provide robust wear components designed for demanding mining, mineral processing, material handling and heavy industrial applications.
Tungsten carbide blocks, tiles or inserts are strategically positioned on critical wear areas and securely bonded to the steel substrate through a controlled vacuum brazing process. The result is a composite wear component that combines high wear resistance, reliable carbide-to-steel bonding and structural toughness.
Why Vacuum Brazed Tungsten Carbide?
Conventional wear-resistant steels can experience rapid material loss when exposed to highly abrasive ores, minerals, sand and other hard particles. Cemented tungsten carbide provides substantially higher hardness and wear resistance, while the steel substrate provides the mechanical strength required for installation and structural loading.
Vacuum brazing enables tungsten carbide blocks to be securely integrated onto selected wear surfaces, allowing high-performance carbide protection to be concentrated in critical wear zones while retaining the strength and cost efficiency of a steel substrate.
Key Benefits
- Exceptional abrasion and erosion resistance
- High-hardness WC-Co wear surface
- Strong carbide-to-steel bonding
- Excellent combination of hardness and structural toughness
- Localized protection of critical wear zones
- Custom carbide block patterns and layouts
- Multiple carbide grades available
- Extended component service life
- Reduced maintenance and replacement frequency
- Custom manufacturing from customer drawings
Industries & Applications
Mining & Mineral Processing
HPGR components • Ore handling • Mineral processing
Crushing & Comminution
Crusher components • Impact blocks • Feed plates • Wear segments
Bulk Material Handling
Chutes • Hoppers • Feed systems • Conveyor wear components • Deflectors
Mixing & Heavy Processing
Mixer paddles • Mixing blades • Scrapers • Wear plates • Custom components
Application-Specific Carbide Layout
The most effective wear solution is not necessarily achieved by covering the entire component with tungsten carbide. IntegriMat can develop application-specific carbide layouts that concentrate wear protection in the areas where it is most needed.
Depending on the application, carbide blocks can be arranged as:
- Full-area carbide coverage
- Partial wear-zone protection
- Edge protection
- Impact-zone reinforcement
- Directional carbide patterns
- Customized tile or block arrangements
This approach allows the component to maintain the structural advantages of steel while providing tungsten carbide protection at the critical wear surfaces.
Tungsten Carbide Material Selection
The performance of a vacuum brazed wear component depends not only on the brazing process but also on selecting the appropriate cemented tungsten carbide grade. IntegriMat offers a range of WC-Co carbide grades with different combinations of cobalt content, carbide grain size, density, hardness and transverse rupture strength.
Higher-hardness grades generally provide greater resistance to abrasive wear, while grades with higher binder content can provide increased toughness for applications involving greater mechanical loading or impact.
The table above provides available carbide grades together with ISO reference classification, Co/Ni binder content, carbide grain size, density, HRA hardness, transverse rupture strength and recommended application range.
Not Sure Which Grade to Select?
Our engineering team can recommend an appropriate carbide grade based on the dominant wear mechanism, abrasive material, particle characteristics, impact severity, mechanical loading, operating temperature, component geometry and required service life. Provide us with information about your application, and we will recommend an appropriate carbide grade based on:
- Dominant wear mechanism
- Abrasive material
- Particle size and hardness
- Impact severity
- Mechanical loading
- Operating temperature
- Component geometry
- Base material
- Required service life
Custom Carbide Geometry & Configuration
Vacuum brazed wear components can be engineered according to the geometry and wear pattern of the application. Available configurations can include:
- Square carbide tiles
- Rectangular carbide blocks
- Carbide strips
- Carbide inserts
- Custom-shaped carbide segments
- Different carbide thicknesses
- Different grain sizes and binder contents
- Customized carbide spacing and coverage
The carbide geometry and arrangement can be optimized according to the direction of material flow and the location of the highest wear.
From Drawing to Finished Wear Component
IntegriMat can support your project from the initial component requirement through delivery of the finished wear-resistant component.
1. Drawing or Component Information
Send us your drawing, dimensions, photographs, existing component or worn-part information.
2. Application & Wear Review
We evaluate the component geometry, operating conditions and dominant wear mechanisms.
3. Material & Carbide Grade Selection
The steel substrate, WC-Co grade, carbide geometry and wear-protection layout are selected according to the application requirements.
4. Component Manufacturing
The base component is manufactured according to the approved drawing and dimensional requirements.
5. Carbide Placement & Vacuum Brazing
Tungsten carbide blocks, tiles or inserts are positioned in the designated wear zones and bonded to the component using a controlled vacuum brazing process.
6. Quality Review
The finished component is reviewed for dimensional requirements, carbide placement and overall manufacturing quality.
7. Finished Wear Component
The completed tungsten carbide protected component is supplied ready for installation or further integration into your equipment.
