Research on the effects of the abrasion resistant coating (CrC, WC wire, WC plate) of refractory monolithic mixer beaters to beater life

By this study, it is aimed to solve an industrial problem. Three different types of coatings were tried and tested to prevent the severe abrasion problems of the refractory monolithic mixer beaters used for material preparation in refractory industry and to extend their lifetime. "CRC, WC Wire, and WC Plate" coated blades were installed together in a batch monolithic mixer to run simultaneously, at the Factory of Kütahya Magnesite Refractory Corporation. These blades (beaters) have been observed for about one year and the microstructures of the wearing parts were analyzed. The longest lifetime of all is reached with the WC Plate coating which is provided through powder metallurgy, furthermore a typical production loss of $510.000 per year for one mixer were prevented by the coating cost of $3.780. A sample application about the uses of Kaizen and 6-Sigma methods, in order to reach correct evaluations about wearing parts – abrasive effects - abrasion conditions at an abrasion problem, is also included in this study. The use of these types of methodologies is of great importance to achieve the shortest path to the solution.