If abrasion takes place under high loads, including impacting situations where erosion is prevalent, then hardness alone will not be a reliable parameter on which to select the appropriate surface. This would be the case in areas like coal chutes, mining conveyors, diggers, crushers, millers, extruders, cutters, compactors, and erosive situations like turbines, impellers and pipework.

The surface must not only be hard, it must be tough and resilient and must be able to withstand high specific loading without deforming into the substrate below.

Before continuing with the analysis, you should read the section on high stress abrasion.

The base material

The substrate is most likely to be constructional steel or low alloy tool steels (e.g. the B Series) made in plate form.

Surface Engineering Options

These are few and are entirely limited to:

1. Welded or Spray-Fused Nickel or cobalt-based materials with high carbide content, deposited to at least 2mm thick.
2. Thermally Sprayed and HIPPED Nickel and iron-based materials with high carbide content (Tungsten and Chrome), deposited to at thicknesses of 5mm or more.
3. High-Velocity Thermally Sprayed Nickel or cobalt-based cermets with low porosity and high bond integrity, at least 1mm thick.
4. Elastomer-based Coatings for high angle erosive situation where the abrasive (cutting) element.

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