Wear-resistant Ceramic Rubber Composite Liner丨Three in One丨Small Porcelain

Inmines,electrical power, building materials,metallurgyIn the production site of the industry, chutes, pipe elbows, cyclones, ball mills and other key equipment are subjected to severe wear and tear caused by material scouring and impact every day. Traditionalmanganese steel linerEasily deformed, frequent replacement, pure rubber liner wear-resistant insufficient, frequent downtime for maintenance not only pull down production efficiency, but also let the enterprise to bear high maintenance costs -- equipment wear problems, has long been a constraint on industrial production "invisible stumbling block".

And now.Wear-resistant ceramic rubber composite linerThe appearance of this product completely breaks this predicament. With the core advantages of "high abrasion resistance, impact resistance, easy installation and long life", it has become the preferred solution for wear protection of industrial equipment.

tripleStructure: Wear-resistant, cushioning, stable in one step

Different from the limitation of single material liner, the wear-resistant ceramic rubber composite liner adopts the three-in-one design of "ceramic layer + rubber layer + metal layer", which is molded at one time through hot vulcanization process, with no adhesive between the layers, and the bonding strength is far more than the traditional laminating process, so that the protective effect is more long-lasting.

Ceramic layer: 92% high alumina ceramics, wear-resistant performance

select and usealuminum oxideHigh-alumina ceramics with a content of ≥92% have a hardness of 9 on the Mohs scale (second only to diamonds), with a much lower volumetric wear than ordinary ceramics.abrasion resistant materialIt can easily withstand the continuous scouring of hard materials such as sand, gravel and ore, and its wear life is 3-5 times longer than that of traditional manganese steel liners.

Rubber layer: natural rubber / styrene-butadiene rubberCushioning and Noise Reduction

The middle layer is made of highly elastic natural rubber or styrene-butadiene rubber (SBR), which can effectively absorb the impact generated by the impact of the material to avoid damage to the equipment shell due to the impact; at the same time, the damping characteristics of the rubber can significantly reduce the noise of the flow of materials to improve the working environment in the workshop.

Metal layer: Q235 / abrasion-resistant steel backing plate, solid installation without falling off

The bottom layer is equipped with Q235 steel or wear-resistant steel backing plate with bolt holes, the diameter of which is 2-4mm larger than that of the bolt, which is suitable for different equipment installation needs, and it is not easy to be loosened after the bolts are fixed, which solves the pain point of traditional liner plate, "difficult to install and easy to fall off".

Small ceramic tile design: adapted to complex working conditions, maintenance costs are greatly reduced.

For curved and shaped parts commonly found in industrial equipment (e.g. pipe elbows, cyclones), the liner is designed with small-sized ceramic blocks, bringing three core advantages.

Curved surfaces fit more accuratelySmaller tiles can be flexibly adapted to the curved and corner structures of the equipment, and the fit is much better than that of larger tiles.Ceramic LinerThe product is designed to avoid localized wear and tear caused by a poor fit.

Partial replacement saves moneyEven if a single piece of ceramic is damaged due to extreme conditions, the liner does not need to be replaced as a whole, only the damaged part needs to be replaced, which reduces the maintenance cost by more than 70% and minimizes downtime losses.

Thermal stress anti-cracking: Small ceramic tiles reserved between the rubber expansion joints, can absorb temperature changes in the operation of the equipment (-30 ℃ ~ 120 ℃ temperature range) brought about by thermal expansion and contraction, to completely avoid ceramic cracking due to thermal stress extrusion, to extend the overall service life.

Hot vulcanization process: detail control, building a solid foundation of quality

High-quality performance comes from the strict requirements of the process. The hot vulcanization molding process of wear-resistant ceramic-rubber composite liners is precisely controlled at every step.

Surface treatment: reinforced adhesion

The ceramic surface is sandblasted and roughened, the metal backing plate is phosphatized, and then coated with CHEMLOK 205+238 two-component special adhesive to ensure that the three layers of material are tightly bonded to prevent inter-layer peeling.

Positioning holes: adapted to the installation

The metal back plate is precisely punched according to the equipment requirements, and the hole diameter is 2-4mm larger than the bolt, leaving space for mounting and adjustment, avoiding the installation problems caused by the size deviation.

Vulcanized molding: high temperature and high pressure locking performance

Ceramics, rubber, metal layers stacked into a special mold, in 150 ℃ ± 5 ℃ high temperature, 12MPa high-pressure environment vulcanization for 20 minutes, so that the rubber completely cross-linked and penetrate into the ceramic gap to form a "gapless integrated structure", the impact strength of the enhancement of 40%, even when subjected to high-frequency material impact is not easy to damage. It is not easy to be damaged even under high-frequency material impact.

Widely adapted: covering multiple industries and solving the real pain points.

From the ore conveying chute in mines, to the coal mill lining in the power industry, to the cyclone separator in building materials factories, to the corrosive material pipeline in chemical plants, wear-resistant ceramic rubber composite liner can play an excellent protective role.

Replace the traditional manganese steel liner, weight reduction 30%, reduce equipment load bearing.

It is suitable for a wide range of material scenarios, whether it is dry grinding, wet grinding, or corrosive materials, all of which can be protected stably.

The maintenance cycle is extended to 2-3 years after installation, saving companies tens of thousands of dollars in maintenance costs each year.

Choose wear-resistant ceramic rubber composite liner, not only to choose a wear-resistant products, but also to choose a "high efficiency, low cost, long cycle" of the production security program. From now on, the wear and tear of the equipment is no longer a worry, the production efficiency is high!

In order to help industrial enterprises to accurately select and evaluate product suitability, the following from theCeramic layer, rubber layer, monolithic product, metal layerFour core components, listed in detailWear-resistant ceramic rubber composite linerThe key performance parameters, all data are verified by third-party testing organizations to ensure the authenticity and reliability.

I. Ceramic layer (high aluminum ceramics) performance parameters

act aslinerThe core wear-resistant parts of the high alumina ceramic layer directly determines the overall wear-resistant life of the product, the specific parameters are as follows:

parameter class	Specific indicators	Test Standards	core value
aluminum oxidequantity contained	≥92% (can be customized 95% high alumina type)	GB/T 25145-2010	The higher the content, the greater the hardness and abrasion resistance.
Mohs hardness	9 grade (second only to diamond)	GB/T 16534-2009	Resistant to high hardness materials (e.g. ores, gravel) washing away
bulk density	≥3.6 g/cm³	GB/T 25995-2010	The higher the density, the denser the structure and the more resistant to wear and tear
compressive strength	≥2000 MPa	GB/T 25145-2010	Withstand high-pressure impact of materials without breaking
Fracture toughness	≥4.5 MPa-m¹/²	GB/T 23806-2009	Avoid chipping of ceramics due to impact
Volumetric wear	≤0.03 cm³/1.61km	ASTM G65-2016	The wear life ismanganese steel3-5 times that of the liner
temperature range	-50℃~150℃ (short-term 200℃)	GB/T 16536-2008	Suitable for high temperature conditions (e.g. coal mills in power plants)

Second, rubber layer (natural rubber /) styrene-butadiene rubber) Performance Parameters

The rubber layer assumes the function of buffer, noise reduction and impact resistance, and its elasticity and aging resistance directly affect the overall stability of the liner:

parameter class	Natural Rubber (NR) Indicators	Styrene-Butadiene Rubber (SBR) Indicators	Test Standards	core value
Shore Hardness (Type A)	60±5 HA	65±5 HA	GB/T 531.1-2008	Balanced elasticity and support to avoid excessive deformation
tensile strength	≥18 MPa	≥15 MPa	GB/T 528-2009	Withstand material pulling without tearing
Elongation at break	≥500%	≥450%	GB/T 528-2009	Reduces equipment damage by absorbing large deformations during shock absorption
tear strength	≥35 kN/m	≥30 kN/m	GB/T 529-2008	Resistant to cuts from sharp edges of materials
Aging resistance	70℃×168h Aging: tensile strength retention rate≥80% elongation at break retention rate≥70%	70℃×168h Aging: tensile strength retention rate≥75% elongation at break retention rate≥65%	GB/T 3512-2014	No hardening and cracking for long term use, prolonging liner life
noise reduction	≥15 dB (vs. metal liner)	≥12 dB (vs. metal liner)	GB/T 23466-2009	Improvement of workshop noise environment, in line with industrial environmental standards

III. Overall products (triple(Composite Structure) Performance Parameters

Through thermal sulphurmetallurgyThe key parameters of the art-molded monolithic liner, which has to meet the combined requirements of "Wear Resistance + Impact Resistance + Ease of Installation", are as follows:

parameter class	Specific indicators	Test Standards	core value
Interlayer bond strength	≥5 MPa (ceramic - rubber) ≥8 MPa (rubber - metal)	GB/T 14522-2008	Eliminate interlayer peeling and shedding, and adapt to high-frequency vibration conditions.
impact strength	≥12 kJ/m² (20°C room temperature)	GB/T 1843-2021	Withstand high speed impacts (e.g. chute drop) without breakage.
Overall temperature range	-30℃~120℃ (long term) -50℃~150℃ (short term)	GB/T 2411-2008	Suitable for most industrial equipment conditions (e.g., chemical piping.),mines(Chute)
Installation Adaptability	Bolt hole tolerance: ±0.5 mmCustomizable size: 100×100mm~1000×500mm	GB/T 1804-2000	Adapts to different equipment installation needs, reducing the amount of on-site processing
weight comparison	Lighter than the same area of manganese steel liner 30%~40%	GB/T 28738-2012	Reduces equipment loads and extends equipment rack life
service life	2 to 5 years (depending on operating conditions)	Measured data from industrial sites	Reduces maintenance costs by reducing downtime replacement frequency

Fourth, the metal layer (Q235 steel / abrasion-resistant steel backing plate) performance parameters

As a support and mounting carrier, the metal backing plate needs to be strong and corrosion-resistant:

parameter class	Q235 Steel Index	Wear-resistant steel (NM400) index	Test Standards	core value
yield strength	≥235 MPa	≥400 MPa	GB/T 700-2006	Withstand the weight of the liner and material without bending
tensile strength	375~500 MPa	600~800 MPa	GB/T 700-2006	Avoid backplate breakage due to bolt pulling during installation
corrosion resistance	After surface phosphating treatment: Salt spray test ≥ 48h No corrosion	After surface phosphating + spraying treatment: salt spray test ≥ 96h No rusting	GB/T 10125-2021	Adapt to wet and dusty working conditions (e.g. mines, power plants)
Thickness Specification	3~6 mm (conventional)	5~8 mm (high impact conditions)	Customized standards	Balanced strength and weight for different equipment loads