Engineered for the most diverse of operations, the Kennametal Conforma Clad can be applied to mixer blades to improve the life of the tool and reduce breakage of the carbide from the blades. In this solution, you’ll find out about Conforma Clad, common types of mixer blades, and the great results from our unique coating when compared to standard carbide blades.
What is Conforma Clad?
Conforma Clad is a uniquely layered coating that incorporates a brazing process that combines the hardness of tungsten carbide with the corrosion resistance of nickel-alloy matrix to create a protective barrier to protect equipment from abrasion, erosion, or corrosion. Due to the metallurgical bond, this Kennametal cladding is extremely resilient to chipping, cracking, and flaking.
Mixer Types with Blades
High-intensity mixers with blades need to be robust, durable, and capable of handling abrasive materials effectively. They can be used for mild or heavier applications, depending on the particle size requirements and materials being processed. Each mixer can incorporate different parts to suit specific applications.
Here are some types of mixers and their descriptions that are commonly used for handling abrasive substances:
- Mixer blades, also known as paddle mixers, are often used for mixing, blending, and pushing abrasive materials together. They are generally employed in dry mixing processes and can handle abrasive substances effectively.
- Double planetary mixers feature two blades that rotate on their own axes and around the mixing area. They are often used for highly viscous and abrasive materials, providing thorough mixing and uniform dispersion.
- High-shear mixers use high-speed rotating blades to break down particles and blend abrasive materials. They commonly mix materials that do not blend easily.
There are several other types of mixers with blades including ones that feature welded arms and bolted paddles or bolted arms with bolted paddles. Both can be replaced when the blades are worn or reveal any other types of damage. However, the replacement of these blades can be difficult. Applying the Kennametal Conforma Clad to these blades will minimize blade changes and allow the mixers to operate longer.
Conforma Clad Proven Solution
A customer that uses the incumbent blades has been seeing breakage due to erosion and impact wear after 45 days when using the blades to blend iron ore fines with a binder to create a feed stock and produce pellets. The customer’s goal is to improve the life of their blades and reduce carbide breakage.
That’s where our experts had a chance to provide the customer with Kennametal’s Conforma Clad coated mixing blades with a tungsten carbide tip to prove we can provide better results. Our mixing blades feature the Conforma Clad coating layered over the carbide end to protect the steel base.
Results
The Conforma Clad mixer blades lasted for 4 months compared to the standard blades the customer was using. Not only did the blades last longer when mixing iron ore fines, but they also increased the efficiency of the mixer, and reduced the amount of downtime and cost per blade.
Kennametal should be able to substantiate this claim. This is a performance claim that should have objective support. As this is a claim of superiority, it requires proof that the Conforma Clad mixer blades performed better than the standard blades. To substantiate the “lasted for 4 months” language, it is required that this level of performance must be obtainable by an “appreciable number” of consumers under circumstances normally and expectably encountered by the consumers.
Anatomy of a Mixer
Impeller-bladed mixers for abrasives comprise various parts. Each component supports uniform blending providing the specifically required consistency for the final product.
Common parts include:
- Blades: The blade is the primary element responsible for blending or pushing the materials together.
- End Disc: Stabilizes the mixing process and ensures that the mixing action of the blades remains consistent, preventing unwanted vibrations.
- Bottom Tool: This part helps mix or grind by blending the abrasive materials at the bottom of the mixer.
- Bottom Scraper: Located at the base of the mixer, the scraper dislodges any material that might adhere to the bottom surface.
- Wall Scraper: Like the bottom scraper, the wall scraper is designed to prevent material from adhering to the walls of the mixer.
- Bottom Plate: This is the durable and resistant surface on which the mixing process occurs. It can withstand the abrasive nature of the materials being processed.
Each of these components ensures efficient and uniform mixing of abrasive materials within the high-intensity mixer.
Conclusion
Conforma Clad helps prevent aggressive wear at the tip of the mixing blades. Kennametal wear solutions can be tailored to meet the most demanding applications.
For more information on Kennametal’s Conforma Clad mixing blades, bottom scrapers, and more, contact one of our experts.
The information contained in this report is intended for comparative purposes only and is based upon a limited test sample. The information has no guarantee of actual future results. The information is provided ‘as is’ without any warranty of any kind whether express or implied.
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