WELD OVERLAY, WEAR & ABRASION PROTECTION SOLUTIONS
PRODUCT RANGE
WELD OVERLAY
DGC AFRICA specializes in Weld Overlay Solutions that significantly enhance the durability and performance of industrial equipment operating under harsh conditions. These overlays are meticulously engineered to combat the severe abrasion, impact, and erosion typically encountered in industries such as mining. Adhering to stringent Australian safety standards, these solutions are recognized for their exceptional wear resistance. They are tailored to meet the specific demands of heavy-duty machinery, ensuring extended equipment life and reliability in demanding operational environments.
SUPERIOR WEAR RESISTANCE
Provides enhanced protection against abrasion and impact, which is crucial for the longevity of machinery exposed to severe wear.
CUSTOMIZABLE SOLUTIONS
Specifically engineered to address unique industrial challenges, ensuring optimal performance and fit for specific machinery applications.
KEY FEATURES
BENEFITS
EXTENDED EQUIPMENT LIFE
Significantly increases the lifespan of critical machinery, reducing downtime and maintenance costs.
SAFETY AND COMPLIANCE
Meets high safety standards, ensuring reliable and safe operations in rigorous conditions.
APPLICATIONS
HEAVY INDUSTRY MACHINERY
Particularly effective for components such as crushers, mills, and conveyors that are subject to intense wear and tear.
These characteristics underscore DGC AFRICA’s commitment to providing robust and durable solutions for industries requiring advanced protection against wear and abrasion.
CASTINGS
DGC AFRICA provides a comprehensive array of castings and bi-metallic wear-resistant products tailored for severe material handling applications. These products, crafted from high-quality materials such as NiCr4-600 and CrMo 15 3 white irons, are renowned for their exceptional durability and resistance to wear. The casting process utilizes the latest technologies in pouring and heat treatment, ensuring that each product offers optimal performance in challenging industrial environments. From wear buttons and blocks to custom-fit billets and skirt liners, these castings serve critical roles in mining and other heavy industries, enhancing equipment longevity and operational efficiency.
KEY FEATURES
DIVERSE MATERIALS
Options include NiHard, White Iron, and Chrome Moly, among others.
ADVANCED MANUFACTURING
Utilizes cutting-edge casting and heat treatment technologies.
BENEFITS
SUPERIOR DURABILITY
Designed to withstand severe abrasion and impact.
COST-EFFECTIVE
Provides a durable and economical alternative to OEM parts.
APPLICATIONS
INDUSTRIAL AND MINING SECTORS
Ideal for heavy-duty applications requiring robust wear protection.
This range of cast products ensures that businesses can maintain high productivity and lower maintenance costs, reinforcing DGC AFRICA's commitment to delivering solutions that meet the demands of rigorous industrial activities.
CERAMICS
WEAR RESISTANT
DGC AFRICA offers advanced Wear Resistant Ceramics designed for unmatched durability in high-abrasion environments. Ideal for sectors like coal and ore mineral processing, these ceramics significantly extend service life, enhancing equipment durability and minimizing maintenance downtime. Utilizing high-performance ceramics in areas subject to severe mechanical stress, they improve efficiency by reducing wear-related operational interruptions.
KEY FEATURES
HIGH-PERFORMANCE PROTECTION
Exceptional resistance to wear and abrasion.
ADVANCED MANUFACTURING
Reduces the frequency of maintenance and replacement.
BENEFITS
IMPROVED EQUIPMENT DURABILITY
Enhances the longevity of handling systems.
COST-EFFECTIVE
Minimizes downtimes, enhancing productivity.
APPLICATIONS
INDUSTRIAL AND MINING SECTORS
Ideal for heavy-duty applications requiring robust wear protection.
These ceramics are a cornerstone for maintaining continuous operations in industries facing intense wear, ensuring that your systems operate at peak efficiency for longer periods.
TUNGSTEN
HARD-FACING
DGC AFRICA Tungsten hard-facing solutions, such as EnduraCoat™ and CTC-X®, are engineered to significantly enhance the lifespan of equipment in environments prone to extreme wear. These solutions utilize a unique welding process that embeds tungsten chips into a base metal, providing a wear resistance that far exceeds traditional overlays. Tungsten hard-facing is designed to tackle the toughest abrasion and impact conditions, making it suitable for a variety of industrial applications.
KEY FEATURES
UNMATCHED HARDNESS
Offers supreme hardness and wear resistance.
VERSATILE APPLICATION
Suitable for high-impact and high-abrasion areas.
BENEFITS
EXTENDED EQUIPMENT LIFE
Increases the durability and operational lifespan of machinery.
REDUCTION IN DOWNTIME
Decreases the need for frequent maintenance and repairs.
APPLICATIONS
HEAVY INDUSTRY
Ideal for drilling tools, wear plates, and cutting edges in sectors like mining and construction.
Tungsten hard-facing stands out as an essential solution for industries requiring the highest level of durability and performance, ensuring equipment remains productive under the most challenging conditions.
QUENCHED
AND TEMPERED STEEL
DGC AFRICA offers a diverse range of Quenched and Tempered steel plates, known for their high strength and durability. Utilizing advanced profile-cutting technology, DGC AFRICA can shape steel plates from 1mm to 200mm thick to meet various industrial needs. This steel is notable for its excellent toughness, weldability, and formability, making it ideal for demanding applications like demolition tools, earthmoving buckets, and structural components.
KEY FEATURES
HIGH STRENGTH
Grades like 700 provide exceptional yield strength, greatly surpassing that of standard carbon steel.
VERSATILITY IN PROCESSING
Can be easily cut, welded, and formed using standard practices.
BENEFITS
ENHANCED DURABILITY
Offers extended life expectancy in high-impact and abrasive conditions.
IMPROVED PERFORMANCE
Ensures structural integrity under severe usage scenarios.
APPLICATIONS
HEAVY MACHINERY
Ideal for components such as rippers, lifting tines, and wear liner plates.
STRUCTURAL APPLICATIONS
Suitable for high-stress structural elements in construction and civil engineering.
This steel range is crucial for sectors that require robust materials to withstand tough operating conditions, ensuring reliability and longevity in heavy-duty applications.
TITANIUM CARBIDE
TiC™ Titanium Carbide wear liners from DGC AFRICA combine Tic inserts with a high tensile strength natural rubber matrix and steel backing plates. The Tic inserts are integrated using a hot vulcanization process for superior bond strength, ensuring the inserts remain embedded throughout the liner's lifespan, providing consistent protection against wear and impact. These liners are specifically designed for maximum resistance to abrasion and impact, making them ideal for handling bulk materials in applications involving hard rock and iron ore.
KEY FEATURES
STRONG BONDING
Vulcanization exceeds the tensile strength of the rubber matrix.
DURABILITY
Ensures long-lasting wear and impact resistance.
BENEFITS
CONSISTENT PROTECTION
Maintains performance across the liner's lifespan.
EASE OF INSTALLATION
Modular design and steel backing offer straightforward replacement.
APPLICATIONS
BULK MATERIAL HANDLING
Particularly effective in iron ore and hard rock environments.
This solution is tailored to enhance the durability and effectiveness of equipment used in demanding material handling applications.
STUD WELDING
DGC AFRICA offers an advanced Stud Welding Service featuring three state-of-the-art machines capable of handling stud sizes from M6 to M24. This service ensures precision and reliability by producing digital readouts to confirm each stud is fired to meet international quality standards. The applications of this service are broad, ranging from mild steels to overlay plates and ceramic liners, making it versatile for various industrial needs.
KEY FEATURES
ADVANCED TECHNOLOGY
Ensures accurate stud placement and adherence to strict standards.
VERSATILITY
Capable of applying studs to a wide range of materials.
BENEFITS
RAPID SERVICE
Quick turnaround times for projects.
ECONOMICAL
Cost-effective solution for industrial fastening needs.
APPLICATIONS
BROAD MATERIAL COMPATIBILITY
Suitable for everything from mild steels to bimetallic and ceramic components, enhancing the structural integrity of assemblies in diverse settings.
This service is crucial for projects requiring robust and precise fastening solutions in construction, manufacturing, and beyond.
PRODUCT FACT SHEETS
Is the super extreme in wear resistant liners and is designed for applications that experience severe abrasion, where standard wear plate is ineffective. CTC-X is available with Cemented Tungsten Carbide & Cobalt tiles, in a range of thickness up to 20mm, vacuum brazed to a mild steel backing plate.
ECI EZLIFT & EZPLUG CAPABILITY STATEMENT
DGC AFRICA'S expertise in wearplate manufacturing helps them achieve excellent results through smart, innovative designs to make your wear plate handling safer and more efficient.
Is the super extreme in wear resistant wear plate and is designed for applications that experience severe abrasion, where standard wear plate is ineffective. ECI MAXI is available in a range of thickness between 5mm –15mm.
EC160 CHROMIUM CARBIDE OVERLAY
EC160 is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications.
ECI60 CHROMIUM CARBIDE OVERLAY TECHNICAL DATA SHEET
ECI60 is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications.
CTC6000 CHROMIUM CARBIDE OVERLAY
CTC6000 is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications.
CTC6000 CHROMIUM CARBIDE OVERLAY TECHNICAL DATA SHEET
CTC6000 Is manufactured with high quality materials as a bulk overlay of high chromium, high carbon, tungsten alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications, where fine particle abrasion is present.
ECI60 is a high chromium, high carbon welding wire for hard surfacing components, and undertaking repairs of onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applicationsexisting weld overlay plate.
ECI80 CHROMIUM CARBIDE OVERLAY
ECI80 is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications.
ECI90 CHROMIUM CARBIDE OVERLAY
ECI90 is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications.
ECI90 CHROMIUM CARBIDE OVERLAY TECHNICAL DATA SHEET
Is manufactured with high quality materials as a bulk overlay of high chromium, high carbon alloy onto a base plate utilising submerged arc welding to achieve a wear resistant plate for use in a variety of material handling applications, where fine particle abrasion is present. ECI90 is manufacture with a single layer to achieve optimum metallurgical properties.
Is the new future of wear resistant plate. The nano style microstructure gives EMEX not only superior protection from abrasion, but also unheard of impact resistance! Designed for applications that experience severe abrasion, and impact where standard wear plate and Plasma Transfer Arc (PTA) is ineffective. EMEX is available in a range of thicknesses and is designed to help with weight reduction by applying thinner layers.
Is the new future of wear resistant plate. The Nano style microstructure gives EMEX not only superior protection from abrasion, but also unheard of impact resistance!
ENDURABLOCK products include bi-metallic products, such as: wear buttons, wear blocks, wear bars & wear plates ENDURABLOCK products are used to prolong wear life on fixed and mobile plant equipment subject to high abrasion.
ENDURABLOCK TECHNICAL DATA SHEET
ENDURABLOCK are the range of wear parts that comprise a casting in AS2027-2002 CrMo 15 3 white iron in various shapes vacuumed brazed onto a mild steel backing plate.
ENDURACAST products include bi-metallic products, such as: wear buttons, wear blocks, wear bars & wear plates ENDURACAST products are used to prolong wear life on fixed and mobile plant equipment subject to high abrasion.
ENDURACAST TECHNICAL DATASHEET
ENDURACAST comes in a range of standard sizes and shapes for materials handling applications and are typically available in either NiCr4-600 or CrMo 15 3 white irons.
ENDURACOAT is a Tungsten overlay developed by DGC AFRICA to provide a cost effective solution in prolonging the life of applications and equipment subject to extreme wear.
ENDURATILE CERAMIC LINERS are an excellent wear protection solution for areas subject to extreme sliding and impact abrasion while promoting material flow. ENDURATILE RUBBER-CERAMIC WEAR LINER’S modern design consists of extremely wear-resistant alumina ceramic bonded to a 250-grade steel backing plate with a highly durable natural rubber matrix.
ENDURATILE (ETI) CERAMIC PASTE is a wear-resistant ZAC grain epoxy compound. This has been designed for a highly demanding application where standard epoxy and grouting compounds are unable to perform. The hardness of the ceramic grains is combined with the specially designed interlocking structure to provide a superior mechanical performance.
Comprised of high-quality materials to achieve superior mechanical and physical properties to withstand intense flow applications under extreme conditions. ENDURATILES are made up of very dense, high-grade alumina ceramic tiles, a material almost as hard as diamond. These tiles protect against wear abrasion where commonly found in mining and industrial applications. Typically, alumina ceramic has a wear life 5 times longer to that of Ni-hard. Available off the shelf in 6mm, 12mm, 25mm, and 50mm thicknesses, 150mm x 100mm, and 150mm x 50mm sizes
ENDURATILE RUBBER-CERAMIC WEAR LINER’S modern design consists of extremely wear-resistant Zirconia Toughened Alumina (ZTA) ceramic tiles bonded to a 250-grade steel backing plate with a highly durable natural rubber matrix. ENDURATILE CERAMIC LINERS are an excellent wear protection solution for areas subject to extreme sliding and impact abrasion while promoting material flow.
GROUSER BARS are steel bars welded to the incline of the wheel covers to provide traction for heavy vehicles and are used to replace the grouser treads on tracked vehicles when they have worn down. GROUSER BARS have proved to be the better solution in hard rock mining and extreme tar sand operations.
GROUSER BAR TECHNICAL DATA SHEET
DGC AFRICA supplies grouser bars in quenched and tempered conditions to achieve the hardness required for typical end-user applications.
LINALUS WEAR PLATE is a revolutionary product by Enduraclad designed to remove the necessity of installing sacrificial wear liners. Significantly reducing weight on equipment.
DGC AFRICA cuts and processes all Austenitic grades of steel. The modernized NOMAG steels incorporate excellent forming and welding characteristics. The Balanced Austenitic structure enables it to be used in a variety of applications including where corrosion resistance and sliding coefficient are critical to performance.
THE PLASMA TRANSFER ARC (PTA) surface treatment process plays an important role in the coating of metal surfaces with metallic powder. PTA surfacing is a process that deposits a coating of controlled alloys on mechanical components that are subject to severe wear and/or corrosion, thus extending their service life.
DGC AFRICA has four CNC PROFILE CUTTING MACHINES with the ability to plasma cut steel from 0.5 mm in thickness to 60mm thick and Oxy cut steel to 200mm thick.
DGC AFRICA cuts and processes all standard grades of QUENCHED & TEMPERED (Q&T) STEEL. The modern Q&T steels incorporate micro-alloying practices to ensure Carbon Equivalent (CE) values are as low as possible, whilst allowing mechanical and hardness properties to be met.
DGC AFRICA has three state of art STUD WELDING Machines capable of firing reduced-based studs from M6 to M24 in diameter. The machines produce digital read outs ensuring the stud is fired correctly each time to Australian Standards AS1554 Part 2.
TECHNICAL SUPPORT - STUD WELDING ALTERNATIVE FASTENERS
The following summarises the hardware associated with stud welding supplied with the reduced-based studs welded by DGC AFRICA.
TECHNICAL SUPPORT - STUD WELDING FASTENERS
The following summarises the hardware associated with stud welding supplied with the reduced-based studs welded by DGC AFRICA.
TECHNICAL SUPPORT - STUD WELDING - REDUCED BASE STUDS
The following summarises the scope of stud welding services provided by DGC AFRICA.
TECHNICAL SUPPORT - STUD WELDING - MECHANICAL PROPERTIES GRADE 4.6 vs 8.8
The purpose of this document is to provide some comparative data as a guide on the mechanical properties, including torque requirements of Drawn Arc Reduced Base Studs (Grade 4.6), and Class / Grade 8.8 threaded bar (based on bolt data). (Class and Grade are used interchangeably throughout this document)
DGC AFRICA capability includes the installation of WELD-IN INSERTS as a cost-effective option to allow fastening of liners in position. Although typically installed in weld overlay plate, WELD-IN INSERTS may also be an option for Q&T plate. Insert shape is only limited to whether the internal shape can be machined from “mild steel” bar.