Compared to standard liners, special-shaped liners are significantly more difficult to manufacture. There are two manufacturing processes for wear-resistant ceramic special-shaped liners: direct fabrication according to a drawing, and cutting existing square liners into the desired special-shaped plate. Based on material composition, special-shaped liners can be categorized as pure ceramic liners, ceramic rubber liners, ceramic steel plate liners, and three-in-one liners.
Pure Ceramic Shaped Liner
This is the most basic type, constructed entirely of alumina ceramic through mold forming and sintering to create a specific shape.
Structural Features:
Made of 100% alumina ceramic, with an aluminum content of 92%, 95%, or 99% depending on the application.
The shape can be customized to meet the equipment's needs, such as curved surfaces, cones, bricks with holes or slots, etc.
Key Advantages:
Extreme Wear Resistance: The highest wear resistance of all types.
High Temperature Resistance: Can operate in high-temperature environments for extended periods (depending on the adhesive).
Corrosion Resistance: Unaffected by acids and alkalis.
Lightweight: Less load on equipment than metal liners.
Disadvantages:
Limited Impact Resistance: Risk of breakage when directly impacted by large, high-velocity materials.
High Installation Dependency: Its effectiveness is heavily dependent on the reliability of the adhesive or mechanical fasteners.
Typical Applications:
Primarily used to withstand high abrasion but low impact.
For example: pneumatic conveying pipes, elbows, powder separator blades, and the flat and curved surfaces of various chutes.
Ceramic-Rubber Composite Profiled Liner
Alumina ceramic blocks are securely embedded in a highly elastic, high-strength rubber sheet through a special vulcanization process.
Structural Features:
The ceramic provides a wear-resistant surface, while the rubber acts as a tough base and buffer layer. The ceramic blocks can be square, hexagonal, or round, arranged in a "lattice" pattern within the rubber sheet. Steel bolts or countersunk holes are typically provided on the back for easy installation.
Key Advantages:
Excellent shock and vibration resistance: The rubber base absorbs significant impact energy, protecting the ceramic blocks from shattering.
Anti-clogging: The rubber has a certain degree of elastic deformation and a self-cleaning effect on sticky and wet materials.
Noise Reduction: Effectively reduces noise during material conveying.
Easy Installation: Typically secured by bolts or countersunk screws, making it quick and easy.
Disadvantages:
High-temperature resistance: The rubber base is generally not designed to operate in environments above 100°C for extended periods.
Lower wear resistance than pure ceramic liners: Because the ceramic is not fully covered, the rubber surface can still wear.
Typical Applications:
Primarily used in high-impact, low-to-medium-abrasion, and non-high-temperature applications.
For example: mine chute screens, vibrating feeders, screening equipment, drop hoppers, and other areas subject to the impact of large ore chunks.
Ceramic-Steel Composite Shaped Liner
Alumina ceramic sheets are attached to a tough steel base (usually Q235 or wear-resistant steel) using a high-strength inorganic adhesive or a special welding process.
Structural Features:
A "rigid-hard" composite structure. The ceramic surface resists wear, while the steel provides structural strength and impact resistance. The ceramic and steel can be bonded together using either adhesive bonding or the more reliable "embedded welding" method (where bolts are inserted through the back of the ceramic, then welded to the steel and secured with nuts).
Key Advantages:
Extremely high impact resistance: The combination of hard ceramic and tough steel can withstand gravity shocks that pure ceramic cannot.
Sturdy and non-deformable structure: The steel base ensures the mechanical strength of the entire component.
Flexible Installation: The steel base can be secured using a variety of methods, such as welding and bolting, making it ideal for creating replaceable modular components.
Disadvantages:
Heavyweight: Increases equipment load.
Higher cost: The manufacturing process is more complex than pure ceramic.
Adhesives may fail at high temperatures: If adhesive bonding is used, choose a high-temperature-resistant adhesive.
Typical Applications:
Mainly used in harsh working conditions subject to both high impact and high abrasion.
For example: dump truck bed linings, stacker-reclaimer hoppers, heavy-duty crusher inlets, slurry pump casings, etc.
Three-in-one Special-Shaped Liner
This is the most comprehensive composite liner, combining the advantages of ceramic, rubber, and steel.
Structural Features:
From top to bottom, it consists of three layers:
Surface layer: Alumina ceramic, providing top-tier wear resistance.
Middle layer: High-strength rubber, acting as a buffer layer to absorb impact energy and vibration.
Base layer: Steel, providing ultimate structural strength and a mounting interface.
The ceramic, rubber, and steel are combined into a solid, integrated structure through a high-temperature, high-pressure vulcanization process.
Core Advantages:
Superior overall performance: Combined with extremely high wear resistance (ceramic), strong impact resistance (rubber buffer), and extremely high overall strength (steel).
Optimal energy absorption and noise reduction: The rubber layer has a significant damping effect.
Long service life: Even under extremely harsh operating conditions, its overall service life often far exceeds that of other liner types.
Disadvantages:
Highest cost； Complex materials and manufacturing processes, Heaviest weight； Also not resistant to high temperatures (limited by the rubber layer).
Typical Applications:
Used in the most demanding and severe working conditions, where impact, wear, and vibration all exist.
For example, key areas such as main chutes in large mines, ore bin linings, large dump truck receiving pits, and blast furnace underflow systems in steel mills.
Choosing the right type of liner is a complex engineering decision that requires a comprehensive consideration of factors such as material properties (particle size, hardness, moisture content), head height, flow rate, equipment type, and operating temperature.
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