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USRE30691E - Method of applying a wearing surface - Google Patents

Method of applying a wearing surface Download PDF

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Publication number
USRE30691E
USRE30691E US06/182,031 US18203180A USRE30691E US RE30691 E USRE30691 E US RE30691E US 18203180 A US18203180 A US 18203180A US RE30691 E USRE30691 E US RE30691E
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US
United States
Prior art keywords
particles
resin
further characterized
abrasive
wear
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US06/182,031
Inventor
James R. Hallstrom
Raymond J. Hoffman
Ronald L. Walling
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FEL-PRO CHEMICAL PRODUCTS LP
Wilmington Trust Co
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Publication date
Priority claimed from US238183A external-priority patent/US3876579A/en
Priority claimed from US05/570,194 external-priority patent/US4018944A/en
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Priority to US06/182,031 priority Critical patent/USRE30691E/en
Application granted granted Critical
Publication of USRE30691E publication Critical patent/USRE30691E/en
Assigned to WILMINGTON TRUST COMPANY, RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, A CORP. OF DE., WADE, WILLIAM J., RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, TRUSTEE reassignment WILMINGTON TRUST COMPANY, RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, A CORP. OF DE. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: REXNORD INC.
Assigned to CHEMREX INC., 1209 ORANGE STREET, WILMINGTON, DELAWARE 19801 A DE CORP. reassignment CHEMREX INC., 1209 ORANGE STREET, WILMINGTON, DELAWARE 19801 A DE CORP. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: REXNORD, INC.
Assigned to WILMINGTON TRUST COMPANY AND WADE, WILLIAM J., AS TRUSTEE reassignment WILMINGTON TRUST COMPANY AND WADE, WILLIAM J., AS TRUSTEE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CHEMEX INC., A CORP. OF DE
Assigned to FEL-PRO INCORPORATED reassignment FEL-PRO INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CHEMREX, INC.
Assigned to FEL-PRO CHEMICAL PRODUCTS L.P. reassignment FEL-PRO CHEMICAL PRODUCTS L.P. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: FEL-PRO INCORPORATED
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B24D3/342—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
    • B24D3/344—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent the bonding agent being organic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/18—Cold vulcanisation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/12—Spreading-out the material on a substrate, e.g. on the surface of a liquid
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/14—Polyepoxides
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/43—Thickening agents
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
    • C09D7/62—Additives non-macromolecular inorganic modified by treatment with other compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/32—Wheels, pinions, pulleys, castors or rollers, Rims
    • B29L2031/324—Rollers or cylinders having an axial length of several times the diameter, e.g. embossing, pressing or printing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/10—Metal compounds
    • C08K3/14—Carbides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/16—Solid spheres
    • C08K7/18—Solid spheres inorganic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/02—Ingredients treated with inorganic substances

Definitions

  • This invention is concerned with a method of on-the-job installation of an abrasive resistant coating and a composition for use in performing the method.
  • An object of this invention is a method of installing an abrasive resistant coating on practically any surface subject to wear regardless of its location.
  • Another object is a method of applying such a coating using conventional tools and procedures.
  • Another object is a method of installing an abrasive resistant coating which will conform to the surface to which it is applied.
  • Another object is a wearing composition which may be installed on the job and yet provides a hard wearing surface for areas of severe wear.
  • Another object is a trowelable composition which quickly hardens to provide a surface having high resistance to abrasion.
  • Another object is a method of repairing a worn surface which permits the surface to be put back in operation in a short time.
  • Another object is a wear resistant composition which can be applied to irregular surfaces such as those found in cones, elbows, etc.
  • Another object is an abrasive resistant coating having a secondary abrasive filler of a hardness on the order of that of the material causing the wear.
  • Another object is an abrasive resistant coating which has a fairly long working life in its mixed stage permitting adequate time to trowel it into difficult to reach or large areas, yet which will cure in a relatively short time.
  • Another object is an abrasive resistant coating that is more resistant to wear than Ni-Hard iron.
  • Another object is an abrasive resistant coating having a resistance to wear approaching that of ceramic tile.
  • Another object is an abrasive resistant material that also functions as a corrosion inhibiting coating.
  • Another object is an abrasive resistant coating which contains alumina ceramic particles.
  • Another object is an abrasive resistant coating containing alumina ceramic particles which is mixed on the job and in which the particles will not settle out while the composition hardens.
  • Another object is an abrasive resistant material of the above type that will not settle out in the can.
  • FIG. 1 is a side view, in section, through a typical application in a diagrammatic or schematic representation
  • FIG. 2 is a portion of FIG. 1 on an enlarged scale.
  • This invention is directed to a method of installing an abrasive resistant surfacing on machinery and wearing surfaces on the job. This is accomplished by use of a composition having high alumina ceramic particles and a co-abrasive filler of smaller particles which are about as hard as the material causing the wear.
  • the particles and filler are contained in components which may be mixed together on the job to provide a substance that can be applied by troweling or similar methods to the surface to be protected or repaired.
  • the abrasive resistant coating when mixed has a paste-like consistency which enables it to be applied and to conform to any shape such as cones, elbows and other curved surfaces.
  • the paste-like mixture cures rapidly, permitting the surface to be put back into operation quickly.
  • the coating could have a working life of on the order of 30-45 minutes at 68° F., which allows ample time to trowel the material onto difficult to reach or large surfaces. It will cure for use in 3-16 hours at 70° F.
  • curing time can be reduced by heating metal surfaces to hand warmth or warmer before or after applying the composition. This will reduce the curing or hardening time to, say, approximately 1 hour.
  • a composition usable in the method of this invention may take many different forms.
  • a base or substrate 10 has been shown which may be assumed to be a worn-out part, such as a liner, chute or what-have-you.
  • a coating or composition 12 is superimposed on the surface thereof and, as shown in FIG. 2, in a somewhat schematic or diagrammatic manner, the coating includes a matrix or base substance or bonding agent 14 containing and holding in place large abrasive resistant particles 16 at suitable intervals with smaller abrasive filler particles 18 in the matrix and interposed between and around the larger beads or chips.
  • the matrix material which may be a polymer, bonds to the surface of the part 10 to be protected and holds the larger abrasive resistant particles 16 in position in relation thereto and in relation to each other and also holds the co-abrasive filler particles 18 in a random dispersion throughout the matrix and in position to take the wear.
  • the matrix itself which may include the resin and a thixotropic agent, when mixed and adhering to the surface, acts as a cushion for the large abrasive resistant particles.
  • energy is transmitted to the matrix from the particles and is dissipated. This prevents cracking and breaking of the more brittle large abrasive resistant particles.
  • the co-abrasive or secondary filler particles 18 are of a much smaller size than the primary abrasive resistant particles 16 and these smaller particles fill the voids or interstices between the large abrasive particles.
  • the co-abrasive filler 18 protects the polymer matrix 14 from being worn away from the abrasive resistant particles. As a result, the abrasive resistant particles remain in place in the matrix longer providing a longer wearing surface.
  • the abrasive resistant particles and co-abrasive filler are maintained in suspension in the polymer matrix during mixing and curing operations by means of a thixotropic agent.
  • a more specific and particularly desirable composition is obtained by the use of high alumina ceramic beads as the abrasive resistant particles. More specifically, the use of metal coated alumina ceramic particles of the type sold by Coors Porcelain Company of Golden, Colo. under the trademark METLX has been found to produce an outstanding abrasive resistant coating. This ceramic is a high alumina (90% type) which has very fine grain (crystal) boundaries to give good abrasive resistance. A coating of metal is placed on the surfaces of ceramic particles. It has been found that polymers and other matrices bond better to the metal coating than they do directly to ceramic. The particles used may be on the order of a fraction of an inch, for example approximately 1/16th of an inch, in their largest dimension.
  • a co-abrasive filler found to function particularly well in a wearing composition applied in accordance with the method of this invention may be silicon carbide, 180 mesh size.
  • other fillers may be used as long as they are about as hard as the material being handled, in other words, the material causing the wear on the surface being protected.
  • the following substances may be used as fillers:
  • the cost of the wearing composition used in connection with the method of this invention may be reduced by matching the co-abrasive filler to the material causing wear.
  • the co-abrasive filler may be used as the co-abrasive filler.
  • the composition of the matrix holding the large abrasive resistant particles in position may vary over a wide range.
  • many types of polymers may be used, such as: epoxide polymers; unsaturated polyester (carboxylate-glycol adduct); a polyurethane; a polyimide or polyamide resin or the like.
  • a particular polymer found to function particularly well as the matrix is an epoxy resin containing a thixotropic agent which resin is cured by means of a mixed polyamine/polyamide curing agent.
  • the thixotropic agent used is a pure CALIDRIA asbestos sold under the designation RG-144 by Union Carbide Corporation.
  • Other agents might be Bentonite, fumed silica, M-P-A by Baker Caster Oil, polyacrylamide and so forth.
  • the composition intended for use with the method of this invention it has been found desirable to provide the large abrasive resistant particles and the co-abrasive filler in both the resin and curing components of the epoxy resin composition.
  • the purpose of doing this is two-fold. First, it provides a mixing ratio between the resin and curing components of approximately 2 to 1 whether the components are measured by weight or volume. Second, it provides thorough wetting of all the abrasive particles and co-abrasive filler. A thorough wetting of these materials is difficult to obtain if the materials are provided in only one of the two components.
  • a specific example of a suitable composition for use in practicing the method of this invention is:
  • the resin may be supplied in one can and the curing agent in another, the two being sold together with the resin can being, for example, a one-gallon container and the curing components being in a one-half-gallon can.
  • a one-gallon container for the resin
  • the one-half-gallon can for the curing agent has been found convenient. In such a situation a proportion of the amounts would be emptied from each and thoroughly mixed before application to the surface to be protected. And, if all of the resin and curing agents in the two-can kit are not used at once, the cans may be sealed up and used later.
  • Another example of a suitable composition is as follows:
  • the above composition is believed to have the advantage of better viscosity control.
  • Another example of a suitable composition is as follows:
  • This example is believed to have the advantage of longer term shelf stability and would be suitable for uses or applications that require such.
  • this last example is not a two-component composition but rather only one.
  • the composition of this example can be suitably packaged and applied at the point of use and then cured or hardened by heat. For example, after it is applied, it might be cured for two hours at about 250° F. followed by an additional, say, 6 hour cure at 350° F.
  • the wearing composition may be applied or used on any one of a number of parts or surfaces.
  • Good examples are feed chutes, buckets, hoppers, feed plates, pipe and elbows, side plates, diverter plates, discharge chutes and skirts, sand slinger, and the feed spout of grinding mills. It might also be used on trunnion liners, pump casing, return idlers, screens, dust collectors and cyclones and the like.
  • the above are merely examples and it should be understood that other applications are important, such as the hard surfacing of classifier flights and shoes, the drums of cement trucks, fan blades, the surfacing of pan feeders, cobbler repulp circulators, the buckets and teeth of front end loaders, and so forth.
  • the large abrasive resistant particles have been stated as being high alumina ceramic particles, but a number of other particles could be used, such as boron nitride, tungsten carbide, silicon carbide, boron carbide and the like.
  • the large particles have been shown as generally round or spherical. But, in certain situations, chips might be used. Round particles may be used for a trowelable mix, but in certain applications, chips might be used. For example, if the composition is to be applied or cast, chips would not be objectionable and they might be less expensive. In certain situations, chips could be used in a trowelable mixture. This is particularly true in a casting system where different beads would be appropriate.

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Abstract

A method of on-the-job installation of a coating having high resistance to wear caused by impact, abrasion, erosion and corrosion and a composition for use in performing the method. The method includes the preparation of a trowelable composition containing high alumina ceramic particles and a co-abrasive filler of smaller particles of inorganic and/or metallic origin in a polymer matrix and the application of this material to the surface to be repaired or protected.

Description

This is a continuation of .Iadd.copending .Iaddend.application Serial No. 414,874, filed Nov. 12, 1973, now abandoned .Iadd.which was a division of Serial No. 238,183 filed Mar. 27, 1972, now U.S. Patent No. 3,876,579 issued Apr. 8, 1975.Iaddend..
SUMMARY OF THE INVENTION
This invention is concerned with a method of on-the-job installation of an abrasive resistant coating and a composition for use in performing the method.
An object of this invention is a method of installing an abrasive resistant coating on practically any surface subject to wear regardless of its location.
Another object is a method of applying such a coating using conventional tools and procedures.
Another object is a method of installing an abrasive resistant coating which will conform to the surface to which it is applied.
Another object is a wearing composition which may be installed on the job and yet provides a hard wearing surface for areas of severe wear.
Another object is a trowelable composition which quickly hardens to provide a surface having high resistance to abrasion.
Another object is a method of repairing a worn surface which permits the surface to be put back in operation in a short time.
Another object is a wear resistant composition which can be applied to irregular surfaces such as those found in cones, elbows, etc.
Another object is an abrasive resistant coating having a secondary abrasive filler of a hardness on the order of that of the material causing the wear.
Another object is an abrasive resistant coating which has a fairly long working life in its mixed stage permitting adequate time to trowel it into difficult to reach or large areas, yet which will cure in a relatively short time.
Another object is an abrasive resistant coating that is more resistant to wear than Ni-Hard iron.
Another object is an abrasive resistant coating having a resistance to wear approaching that of ceramic tile.
Another object is an abrasive resistant material that also functions as a corrosion inhibiting coating.
Another object is an abrasive resistant coating which contains alumina ceramic particles.
Another object is an abrasive resistant coating containing alumina ceramic particles which is mixed on the job and in which the particles will not settle out while the composition hardens.
Another object is an abrasive resistant material of the above type that will not settle out in the can.
Other objects may be found in the following specification, claims, and drawings.
FIG. 1 is a side view, in section, through a typical application in a diagrammatic or schematic representation; and
FIG. 2 is a portion of FIG. 1 on an enlarged scale.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is directed to a method of installing an abrasive resistant surfacing on machinery and wearing surfaces on the job. This is accomplished by use of a composition having high alumina ceramic particles and a co-abrasive filler of smaller particles which are about as hard as the material causing the wear. The particles and filler are contained in components which may be mixed together on the job to provide a substance that can be applied by troweling or similar methods to the surface to be protected or repaired.
The abrasive resistant coating when mixed has a paste-like consistency which enables it to be applied and to conform to any shape such as cones, elbows and other curved surfaces. The paste-like mixture cures rapidly, permitting the surface to be put back into operation quickly. The coating could have a working life of on the order of 30-45 minutes at 68° F., which allows ample time to trowel the material onto difficult to reach or large surfaces. It will cure for use in 3-16 hours at 70° F. When necessary, curing time can be reduced by heating metal surfaces to hand warmth or warmer before or after applying the composition. This will reduce the curing or hardening time to, say, approximately 1 hour.
A composition usable in the method of this invention may take many different forms. In the drawing, a base or substrate 10 has been shown which may be assumed to be a worn-out part, such as a liner, chute or what-have-you. A coating or composition 12 is superimposed on the surface thereof and, as shown in FIG. 2, in a somewhat schematic or diagrammatic manner, the coating includes a matrix or base substance or bonding agent 14 containing and holding in place large abrasive resistant particles 16 at suitable intervals with smaller abrasive filler particles 18 in the matrix and interposed between and around the larger beads or chips. The matrix material, which may be a polymer, bonds to the surface of the part 10 to be protected and holds the larger abrasive resistant particles 16 in position in relation thereto and in relation to each other and also holds the co-abrasive filler particles 18 in a random dispersion throughout the matrix and in position to take the wear. The matrix itself which may include the resin and a thixotropic agent, when mixed and adhering to the surface, acts as a cushion for the large abrasive resistant particles. During impact of the material causing wear, such as the various types of ores, sand, gravel, etc., energy is transmitted to the matrix from the particles and is dissipated. This prevents cracking and breaking of the more brittle large abrasive resistant particles.
In such a composition, the co-abrasive or secondary filler particles 18 are of a much smaller size than the primary abrasive resistant particles 16 and these smaller particles fill the voids or interstices between the large abrasive particles. The co-abrasive filler 18 protects the polymer matrix 14 from being worn away from the abrasive resistant particles. As a result, the abrasive resistant particles remain in place in the matrix longer providing a longer wearing surface. The abrasive resistant particles and co-abrasive filler are maintained in suspension in the polymer matrix during mixing and curing operations by means of a thixotropic agent.
While many polymers, abrasive resistant particles, co-abrasive fillers and thixotropic agents may be found suitable for a composition to be used in the method of this invention, a more specific and particularly desirable composition is obtained by the use of high alumina ceramic beads as the abrasive resistant particles. More specifically, the use of metal coated alumina ceramic particles of the type sold by Coors Porcelain Company of Golden, Colo. under the trademark METLX has been found to produce an outstanding abrasive resistant coating. This ceramic is a high alumina (90% type) which has very fine grain (crystal) boundaries to give good abrasive resistance. A coating of metal is placed on the surfaces of ceramic particles. It has been found that polymers and other matrices bond better to the metal coating than they do directly to ceramic. The particles used may be on the order of a fraction of an inch, for example approximately 1/16th of an inch, in their largest dimension.
A co-abrasive filler found to function particularly well in a wearing composition applied in accordance with the method of this invention may be silicon carbide, 180 mesh size. However, other fillers may be used as long as they are about as hard as the material being handled, in other words, the material causing the wear on the surface being protected. By way of example, but not of limitation, the following substances may be used as fillers:
Diamond dust, boron carbide, boron nitride, tungsten carbide alumina ceramic, silica sand, taconite, etc.
The cost of the wearing composition used in connection with the method of this invention may be reduced by matching the co-abrasive filler to the material causing wear. For example, where sand is the abrasive material causing the wear, silica sand or silica flour may be used as the co-abrasive filler.
The composition of the matrix holding the large abrasive resistant particles in position may vary over a wide range. For example, many types of polymers may be used, such as: epoxide polymers; unsaturated polyester (carboxylate-glycol adduct); a polyurethane; a polyimide or polyamide resin or the like. A particular polymer found to function particularly well as the matrix is an epoxy resin containing a thixotropic agent which resin is cured by means of a mixed polyamine/polyamide curing agent. The thixotropic agent used is a pure CALIDRIA asbestos sold under the designation RG-144 by Union Carbide Corporation. Other agents might be Bentonite, fumed silica, M-P-A by Baker Caster Oil, polyacrylamide and so forth.
In the composition intended for use with the method of this invention, it has been found desirable to provide the large abrasive resistant particles and the co-abrasive filler in both the resin and curing components of the epoxy resin composition. The purpose of doing this is two-fold. First, it provides a mixing ratio between the resin and curing components of approximately 2 to 1 whether the components are measured by weight or volume. Second, it provides thorough wetting of all the abrasive particles and co-abrasive filler. A thorough wetting of these materials is difficult to obtain if the materials are provided in only one of the two components.
A specific example of a suitable composition for use in practicing the method of this invention is:
______________________________________                                    
                   Parts by Weight                                        
______________________________________                                    
Resin Component                                                           
"EPON" Resin 828, Shell                                                   
Chemical Corporation 50.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  3.0                                                  
TiO.sub.2, "TITANOX" National                                             
Lead Co.             1.0                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         23.3                                                 
Coors "METLX" Pellets                                                     
                     130.0                                                
                     207.3                                                
Curing Component     Parts by Weight                                      
Jefferson AL-1, Jefferson                                                 
Chemical Company     10.0                                                 
Vanamid 50-40, R. T. Vanderbilt                                           
Company              10.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  2.0                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         21.7                                                 
Coors "METLX" Pellets                                                     
                     70.0                                                 
                     113.7                                                
______________________________________
In this example the resin may be supplied in one can and the curing agent in another, the two being sold together with the resin can being, for example, a one-gallon container and the curing components being in a one-half-gallon can. This is merely an example and it should be understood that any suitable sizes could be used depending upon the needs of the customer and the amount of material to be used in an application. But a one-gallon can for the resin and the one-half-gallon can for the curing agent has been found convenient. In such a situation a proportion of the amounts would be emptied from each and thoroughly mixed before application to the surface to be protected. And, if all of the resin and curing agents in the two-can kit are not used at once, the cans may be sealed up and used later.
The above example, when mixed, applied, and cured, has the following characteristics:
______________________________________                                    
Tensile Strength     4,000   psi                                          
Compressive Strength 15,000  psi                                          
Heat Deflection                                                           
Temperature          195° F.                                       
Lap Shear Strength   2,000   psi                                          
Gel Time             90      min.                                         
Working Time         20      min.                                         
                     at      70° F.                                
______________________________________
Another example of a suitable composition is as follows:
______________________________________                                    
                   Parts by Weight                                        
______________________________________                                    
Resin Component                                                           
Dow DER 330, Dow Chemical Co.                                             
                     50.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  3.0                                                  
TiO.sub.2, "TITANOX", National                                            
Lead Co.             1.5                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         23.3                                                 
Coors "METLX" Pellets                                                     
                     130.0                                                
                     207.8                                                
Curing Component                                                          
Jefferson AL-1, Jefferson                                                 
Chemical Company     10.0                                                 
Versamid 140, General Mills                                               
                     10.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  1.0                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         21.7                                                 
Coors "METLX" Pellets                                                     
                     70.0                                                 
                     112.7                                                
______________________________________
The above composition is believed to have the advantage of better viscosity control.
Another example of a suitable composition is as follows:
______________________________________                                    
                   Parts by Weight                                        
______________________________________                                    
Resin Components                                                          
"EPON" 3280, Shell                                                        
Chemical Corporation 50.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  2.5                                                  
TiO.sub.2, "TITANOX", National                                            
Lead Co.             1.5                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         23.3                                                 
Coors "METLX" Pellets                                                     
                     130.0                                                
                     207.3                                                
Curing Components                                                         
TETA (D.E.H. 24), Dow Chemical                                            
                     10.0                                                 
Polyamine PA-400, Jefferson                                               
Chemical Company     10.0                                                 
Asbestos, "RG-144", Union                                                 
Carbide Corporation  2.0                                                  
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         21.7                                                 
Coors "METLX" Pellets                                                     
                     70.0                                                 
                     113.7                                                
______________________________________
This example is believed to have the advantage of longer term shelf stability and would be suitable for uses or applications that require such.
Another example is as follows:
______________________________________                                    
Resin Components     Parts by Weight                                      
______________________________________                                    
Dow DER 330, Dow Chemical                                                 
                     100.0                                                
Silicon Carbide, 180 X, Simonds                                           
Abrasive Div., The Wallace                                                
Murray Corp.         90.0                                                 
Coors "METLX" Pellets                                                     
                     400.0                                                
Trimelitic Anhydride, Amoco                                               
Chemical Company     50.0                                                 
                     640.0                                                
______________________________________
It will be noted that this last example is not a two-component composition but rather only one. The composition of this example can be suitably packaged and applied at the point of use and then cured or hardened by heat. For example, after it is applied, it might be cured for two hours at about 250° F. followed by an additional, say, 6 hour cure at 350° F.
In certain situations, two parts of Stannous Octoate, supplied by the National Lead Company, could be added to the single component example to reduce the curing time to something on the order of five minutes at 300° F.
The wearing composition may be applied or used on any one of a number of parts or surfaces. Good examples are feed chutes, buckets, hoppers, feed plates, pipe and elbows, side plates, diverter plates, discharge chutes and skirts, sand slinger, and the feed spout of grinding mills. It might also be used on trunnion liners, pump casing, return idlers, screens, dust collectors and cyclones and the like. The above are merely examples and it should be understood that other applications are important, such as the hard surfacing of classifier flights and shoes, the drums of cement trucks, fan blades, the surfacing of pan feeders, cobbler repulp circulators, the buckets and teeth of front end loaders, and so forth.
The large abrasive resistant particles have been stated as being high alumina ceramic particles, but a number of other particles could be used, such as boron nitride, tungsten carbide, silicon carbide, boron carbide and the like.
The large particles have been shown as generally round or spherical. But, in certain situations, chips might be used. Round particles may be used for a trowelable mix, but in certain applications, chips might be used. For example, if the composition is to be applied or cast, chips would not be objectionable and they might be less expensive. In certain situations, chips could be used in a trowelable mixture. This is particularly true in a casting system where different beads would be appropriate.
The examples both as to time and temperature given hereinabove are merely for purposes of description. The curing time is flexible and can be varied by modifying the formula somewhat to fit or suit any particular application. The same is true of curing temperature.

Claims (7)

We claim:
1. A method of making a surface substantially more wear resistant where the surface is subject to wear caused by impact, abrasion, erosion or corrosion, including the steps of supplying (a) an uncured curable crosslinkable thermosetting resin and (b) a curing agent for the resin, separately, in about a 2 to 1 ratio, and a thixotropic agent in an amount sufficient to prevent settling, intermixing independently in (a) and (b) both large abrasion resistant ceramic particles and much smaller coabrasion resistant filler particles of a hardness on the order of that of the material causing wear with the smaller particles dispersed in random fashion among the larger particles, mixing all the ingredients and applying the resultant mixture to the surface subject to wear and allowing it to cure and firmly adhere to the surface.
2. The method of claim 1 further characterized in that the large abrasion resistant ceramic particles are metal coated alumina ceramic beads.
3. The method of claim 1 further characterized in that the large abrasion resistant ceramic particles are spherical beads.
4. The method of claim 1 further characterized in that the smaller co-abrasion resistant filler particles are silicon carbide.
5. The method of claim 1 further characterized in that the resin is an epoxy resin.
6. The method of claim 1 further characterized by and including the step of mixing both large and smaller particles separately in the resin and curing agent prior to mixing the resin and curing agent together.
7. The method of claim 1 further characterized in that the large abrasion resistant ceramic particles are on the order of 1/16 inch in their largest dimension and the smaller coabrasion resistant filler particles are on the order of 180 mesh size.
US06/182,031 1972-03-27 1980-08-28 Method of applying a wearing surface Expired - Lifetime USRE30691E (en)

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US238183A US3876579A (en) 1972-03-27 1972-03-27 Composition to be applied to a surface to increase its wear resistance
US05/570,194 US4018944A (en) 1973-11-12 1975-04-21 Method of applying a wearing surface
US06/182,031 USRE30691E (en) 1972-03-27 1980-08-28 Method of applying a wearing surface

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Publication number Priority date Publication date Assignee Title
FR2639362A1 (en) * 1988-11-23 1990-05-25 Freecom Inc ABRASION RESISTANT ENHANCED COATING AND METHOD OF APPLICATION
US5316521A (en) * 1991-12-31 1994-05-31 Ayre Jr Fred P Textured oil-free bowling lane surface
US6035591A (en) 1997-08-13 2000-03-14 Hicks; James K. Method and apparatus for providing concrete products having improved surface and structural characteristics
EP1216759A2 (en) * 2000-12-22 2002-06-26 Tocchio S.r.l. Method and unit for producing highly abrasion-resistant protective coverings, in particular for floor and work surfaces
US20020194796A1 (en) * 2001-06-21 2002-12-26 Kress Russell L. Modular living enclosure
US6755720B1 (en) * 1999-07-15 2004-06-29 Noritake Co., Limited Vitrified bond tool and method of manufacturing the same
US20080129044A1 (en) * 2006-12-01 2008-06-05 Gabriel Eduardo Carcagno Nanocomposite coatings for threaded connections
US10513793B2 (en) 2014-02-19 2019-12-24 Tenaris Connections B.V. Threaded joint for an oil well pipe

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Cited By (14)

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Publication number Priority date Publication date Assignee Title
FR2639362A1 (en) * 1988-11-23 1990-05-25 Freecom Inc ABRASION RESISTANT ENHANCED COATING AND METHOD OF APPLICATION
US5316521A (en) * 1991-12-31 1994-05-31 Ayre Jr Fred P Textured oil-free bowling lane surface
US6035591A (en) 1997-08-13 2000-03-14 Hicks; James K. Method and apparatus for providing concrete products having improved surface and structural characteristics
US6755720B1 (en) * 1999-07-15 2004-06-29 Noritake Co., Limited Vitrified bond tool and method of manufacturing the same
US7044990B2 (en) 1999-07-15 2006-05-16 Noritake Co., Limited Vitrified bond tool and method of manufacturing the same
US20040185763A1 (en) * 1999-07-15 2004-09-23 Noritake Co., Limited Vitrified bond tool and method of manufacturing the same
EP1216759A2 (en) * 2000-12-22 2002-06-26 Tocchio S.r.l. Method and unit for producing highly abrasion-resistant protective coverings, in particular for floor and work surfaces
EP1216759A3 (en) * 2000-12-22 2004-01-21 Tocchio S.r.l. Method and unit for producing highly abrasion-resistant protective coverings, in particular for floor and work surfaces
US20020194796A1 (en) * 2001-06-21 2002-12-26 Kress Russell L. Modular living enclosure
US20080129044A1 (en) * 2006-12-01 2008-06-05 Gabriel Eduardo Carcagno Nanocomposite coatings for threaded connections
US8322754B2 (en) 2006-12-01 2012-12-04 Tenaris Connections Limited Nanocomposite coatings for threaded connections
US8758876B2 (en) 2006-12-01 2014-06-24 Tenaris Connections Limited Nanocomposite coatings for threaded connections
US10513793B2 (en) 2014-02-19 2019-12-24 Tenaris Connections B.V. Threaded joint for an oil well pipe
US11359303B2 (en) 2014-02-19 2022-06-14 Tenaris Connections B.V. Threaded joint for an oil well pipe

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