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Wear is a System Problem, Not a Single Elbow
Wear is a System Problem, Not a Single Elbow
Elbows fail for different reasons. Abrasion, particle impact, slurry acceleration, turbulence, chemical additives, and velocity change all contribute to material loss. A single "hard product" is rarely correct for every zone.
In chrome carbide overlay wear pipe systems, these factors demand customized solutions beyond commodity CCO to prevent premature failure in abrasive mining environments.
Our role isn't just to supply elbows.
We match overlay chemistry and thickness to the actual wear mode.
How We Select a Wear System
How We Select a Wear System
We evaluate:
Velocity and density of slurry or paste
Mineral hardness & particle size distribution
Chemical additives affecting overlay chemistry
Acceleration and turbulence at the direction change
Impact zones at the slurry entry or exit point
If the overlay can’t survive those conditions, it’s the wrong solution — no matter who makes it.
Where Wear Happens (and Why)
Where Wear Happens (and Why)
Wear is not uniform — elbows need different carbide structures than reducers or straight sections.
Understanding these zones in abrasion-resistant wear pipe helps select the right CCO chemistry.
Backfill Elbows
Backfill Elbows
Turbulent direction change + high-density abrasion
Typically requires high-carbide volume + impact tolerance (Addressed by UTP's high-carbide surfacing wires for impact tolerance (brochure page 4) see download link at bottom of page)
Slurry Pump Discharge Elbows
Slurry Pump Discharge Elbows
High velocity acceleration + particle impact
Needs toughness + carbide retention under stress
Reducers, Tees & Wyes
Reducers, Tees & Wyes
Velocity change creates abrasion + deflection.
Require a balanced alloy to avoid cracking at transitions.
Hrd Corp™ Overlay Systems
Hrd Corp™ Overlay Systems
Overlay elbows are produced through controlled welding parameters and carbide chemistry, not simply by using “hard wire.” OPC supports elbows with:
Custom carbide-rich overlays for slurry & paste using Voestalpine UTP wire formulations built for mining environments (e.g., self-shielded flux-cored wires for high-productivity anti-wear cladding, brochure page 3)
Impact-tolerant overlays at direction changes
Consistency across elbows and straight sections (no weak links)
We partner with OEM fabrication shops and select overlay chemistries that outlast commodity CCO.
Our Unique Advantage: Empowering Your On-Site Repairs
Our Unique Advantage: Empowering Your On-Site Repairs
Unlike competitors who leave you with no option but complete component replacement, OPC goes beyond manufacturing and supply.
We empower your operations with:
Documentation- including technical specs and mill certifications for the UTP consumables used in fabrication—upon request
On-Site Repair - Always provide an optional backup supply of the exact matching consumables to enable quick fixes
Training - Expert guidance for on-site emergency repairs, allowing your maintenance team to quickly patch and resume operations swiftly
This approach minimizes downtime during unexpected failures, reduces waste through fewer replacements (better for ESG), and extends system life in demanding mining environments.
Why UTP Wire Matters
Why UTP Wire Matters
Most CCOs fail from cracking and carbide washout, not “wearing out.” UTP wire is engineered to:
Control dilution for chemical stability
Retain carbides under impact & acceleration
Reduce cracking that exposes soft base metal
Longer service life isn’t a claim — it’s chemistry.
Understanding Wear Modes in CCO Systems
Understanding Wear Modes in CCO Systems
Correct alloy selection for chrome carbide overlay wear pipe begins with understanding the primary wear mechanism:
Abrasive wear - sliding or gouging contact with rock or sharp mineral content in backfill
Impact wear - repeated mechanical shock or high-energy particle strikes in elbows
Erosive wear - high-velocity slurry or air-stream particle attack in discharge lines
Metal-on-metal wear - friction or galling between contacting pipe components
Thermal wear - heat cycles causing softening or surface breakdown in high-temp applications
Each mode requires specific UTP carbides, hardness profiles, and dilution control.
To see more of the UTP Hardfacing product range, click here → View All UTP Hardfacing & Wear Protection.
Case Study - Enhancing Backfill Durability with WEARCore XD 67-1-0
Case Study - Enhancing Backfill Durability with WEARCore XD 67-1-0
In a field trial at an Ontario mine, Voestalpine Böhler Welding's WEARCore XD 67-1-0 (applied via HRD CORP™-style overlays) extended elbow life in cemented sand paste systems.
Trial Setup
Trial Setup
Conducted at an Ontario mine through Böhler Welding Canada, the trial hardfaced two long-radius pipe elbows with WEARCore XD 67-1-0 using 1.6 mm wire (220-240 A, 26 V).
Key Results
Key Results
- Throughput reached 95,000 tons vs. 50-55,000 tons for conventional CCO—a 73% increase - Minimal loss at 15,000 tons (spiral beads visible); extended beyond standard milestone
Comparison
Comparison
Superior to standard overlays in reducing leakages and downtime.
Benefits
Benefits
Boosts efficiency, supports ESG goals. Contractor noted smooth welding and superior appearance. OPC Industrial & Mining collaborates with Voestalpine to enable such trials and deliver optimized abrasion-resistant solutions for Canadian sites.
Full article: WEARcore XD 67/1-O: The New Age in Backfill Pipe Manufacturing
Need TDS or pricing?
Need TDS or pricing?
Related Categories
Related Categories
UTP Special Alloys | Repair & Maintenance | Hardfacing & Wear Protection | Joining & Cladding
Reference Source
This page is based on the UTP Maintenance 2024 Brochure from voestalpine Böhler Welding, focusing on filler metals for repair, wear protection, and corrosion protection. Download the full brochure PDF.
Need support selecting the correct overlay system?
Need support selecting the correct overlay system?
Get expert guidance on chrome carbide overlay wear pipe for your mining application—request UTP technical support today.
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