HFW Industries offers alternatives. Meanwhile new products drop that help keep plants running.

Tungsten alloys are scarce for American suppliers of machining services, rebuilds, remans and wear parts. As of this writing, a tungsten carbide bar goes for roughly $150/lb and day-to-day double-digit percentage price swings are the norm. Also normal is customers considering alternatives.

HFW Industries has a temporary workaround for the shortage, which has impacted one of its primary lines of business. The company offers thermal-sprayed tungsten carbide coating as wear parts and in rebuilds. Customers outright demand it for its indestructibility, an expert with the company told Coal Age. “These coatings help prevent abrasion and corrosion,” said Jack Watson, business development manager.

The supplier uses a high-velocity oxy-fuel (HVOF) spraying process that offers tight technical control for a more exacting and durable coating. The alloy, such as tungsten carbide, is “heated in a high-pressure flame and propelled at supersonic speeds onto the surface,” company literature said. This “creates a mechanical bond between the coating and the substrate, typically applied at low temperatures, below 300°F.”

Due to the low temperatures involved in the application process, the base metal is not melted. “The result is an extremely dense, hard, and low-porosity coating that provides exceptional resistance to wear, heat, and corrosion,” HFW Industries said. Beyond HVOF, the company also uses flame spray, electric arc metallizing, and plasma spray processes in applying thermal spray coatings.

A similar solution offered by HFW Industries is hardfacing, which involves welding and results in a metallurgical bond with the base metal. “This results in some dilution with the base metal, forming a homogenous alloy weld,” the company said. Whereas hardfacing is ideal for “heavy-wear, high-heat, and structural applications,” HVOF and thermal spray coating is for “when you need tight tolerances, fine finishes, and excellent surface performance.”

Thermal-sprayed coatings are a mismatch in “any environment where the part that is being coated is facing impact,” Watson said. “Because it is only a mechanical bond, you risk the integrity of the coating when there is impact.”

Thermal-sprayed coatings are widely used in a range of applications and industries. It “is used in everything from defense and aerospace applications all the way down to industrial applications like gas turbines and coal plant equipment,” Watson said. “The price has just absolutely skyrocketed over the last several weeks and it is increasingly hard to get,” he said. “Many people won’t even sell it to you.”

In early Q1, “we were buying it at $80/lb to $90/lb,” he said. “Those alone were elevated levels and now some grades are breaking $200/lb.”

The cause of the shortage is the trade war with China. “Tungsten carbide is primarily sourced out of China, and China is heavily restricting supply to the USA,” Watson said. “The largest sources for this outside of China have been severely reduced.”

To cope, “suppliers are rapidly turning to recycled options that are more readily available in North America, Europe and more friendly nations,” he said.

HFW Industries has so far been able to avoid some of the worst consequences. “We have built some really deep relationships with some of our materials vendors,” Watson said. “For the time being we have been able to procure a supply of tungsten carbide.”

That supply is pricey. “Some customers are willing to pay the premium because tungsten carbide is respected and it has superior wear resistance,” he said.

For those unwilling to pay the premium, the supplier offers “alternatives that may be considered. There are other materials,” Watson said. “They may not have quite the wear resistance of tungsten carbide, but they can offer similar protection at a fraction of the cost.”

For example, “chrome carbide is very similar to tungsten carbide,” he said. “It doesn’t have quite the hardness, but it has strong wear resistance and excels in environments and applications where corrosion is an issue.” It “works well in high-temperature environments.”

Chrome carbide “is used very heavily in turbo machinery applications that are high temperature,” Watson said. “But it doesn’t have to be,” he said. “It can be used in more general industrial applications where you are looking for wear and corrosion resistance.” And chrome carbide “is approximately half the cost” of tungsten carbide.

Watson described thermal spray coating and hardfacing as the “heart” of HFW’s operation. “The big thing with us is we have the ability to perform most of the work in-house,” he said. “It saves customers a lot of time and money and complexity when they can work with us and we can perform most of the work.”

HFW Industries, which also offers machining, grinding, manufacturing, rebuilds, and inspection services, sees consistent demand for tungsten carbide for fan blade rebuilds. Fan blades for mine fans and plants can wear down until they fail. “Dust particles flying across the blade will wear down the blade over thousands of hours of service,” Watson said. “We will take a used blade. We will grind it down. We will remove the nose guards. We will clean it, strip it, and then we will rebuild the profile and weld it.”

In many cases the blades have been abraded to where “a significant percentage of the blade surface is gone,” Watson said. “Our team will completely rebuild that via welding,” he said. “And then we will coat the entire blade with tungsten carbide that is robotically sprayed using the HVOF process.”

The rebuild saves customers “substantial amounts of time and money,” Watson said. “Especially when you consider blades are made from castings.” Castings represent a significant expense and require a comparatively lengthy lead time. “So it is a substantial savings to the customer, especially when you are looking at operators who must be very lean when it comes to costs,” he said. “So, I’m not sure they want to put a ton of new capital equipment into a facility if that equipment may have a limited lifespan.”

HFW Industries rebuilds a range of equipment and parts. “We are kind of known for finding creative solutions to give more equipment new life,” Watson said. “We don’t want to overpromise but our rebuild capabilities have saved customers a lot of money and given them parts that are like new or are in better-than-new condition starting with a used part.”

The supplier also manufactures conveyor assemblies, centrifuge equipment, and filtration components. “We are about 50-50 in our business when it comes to manufacturing equipment new versus rebuilding it,” he said.

In both businesses, the supplier strives to find the most effective and cost-efficient solution for the customer, Watson said. “We are very willing and have a long history of working side by side with our great customers to help them find ways to get the most out of their equipment and their production line.”

Separately, new products that dropped in Q1 and early Q2 reflect the spirit of innovation that answers trending challenges and that keeps plants and operations running.

ASGCO announced the Grizzly Straight-Warp Screw-Splice for splicing conveyor belts. The splice delivers superior strength, durability, and performance in challenging environments, the supplier said.

With a straight-warp carcass construction, the splice features a high-abrasion-resistant rubber compound. “This engineering advancement provides up to a 60% increase in breaking strength, significantly enhancing splicing integrity and extending service life,” ASGCO said.

Benefits offered include reduced downtime and increased operational efficiency, the supplier said. “It’s rugged design ensures consistent performance.”

Force Control reported its air-operated Posistop oil shear motor and coupler brakes are ideal for downhill conveyors. Other applications include hoists, winches, elevators, stackers, loaders and unloaders. “Designed as dynamic brakes,” they “can stop a load as well as hold it,” the supplier said. “Their high-thermal capacity allows higher cycle rates and heavier loads.”

Sold as spring-set pressure-release brakes or as pressure-release brakes, they are often mounted to the back of air motors, “making them well-suited for severe duty environments,” the supplier said.

The brakes are reportedly designed to deliver optimal availability. “Their multi-disc design reduces the inertia of the brake, which puts less load on the motor, and improves efficiency in each cycle,” Force Control said. “All Posistop brakes feature Teflon liners on all piston sealing areas for a smooth response and long service life,” it said. “Because the brakes are air actuated, they function without the problems associated with failed coils, slow response due to counter-electromotive force, additional electrical heat, and the failure of small linkage parts found in electrically actuated brakes.” Built with oil-shear technology, “brake life is often as long as, or longer than, the motor service life.”

Dust, dirt, moisture, and fume proof, they are available in five models, including heavy- and severe-duty designs. They offer torque from 6 lb-ft to 2,030 lb-ft, and fit 56-frame up to 440-frame motors. The torque can be adjusted by changing the number of springs and discs.

“They can be used horizontally or vertically and require minimal air volume up to a maximum of 80 psi,” Force Control said. “They can be furnished mounted on a motor as an assembled brake motor, or installed on a customer’s motor, gear reducer, or machine frame.”

Dedicated flange mountings are available to accommodate IEC, servo and other flange sizes. Also available are shaft connections, including bore and key, split clamped quill, and tapered collet.

Separately, Force Control extended the warranty on its MAGNASHEAR brakes to three years, reportedly the longest warranty in the industry. The brakes use the company’s oil shear technology to “deliver precise stopping and repeatable positioning in demanding high-cycling or reversing applications,” Force Control said. “Because wear is virtually eliminated, MAGNASHEAR brakes require no adjustments and only an annual fluid change, offering a maintenance-free solution for mission-critical uptime.” Applications include cranes, hoists, and winches.

Denso, Inc., reported its Covercoat System for steel protection is engineered for harsh environments and requires minor prep work and no pre-blasting. Reportedly effective almost immediately after application, it provides up to 20 years of corrosion resistance. The system is ideal for maintenance applications, the company said.

The Covercoat System is comprised of a primer that reportedly penetrates rust and displaces moisture, a mastic for smoothing profiles and sealing around bolts and joints, tape, polyester scrim, basecoat for weatherproofing, and an acrylic topcoat. The company said the system minimizes intercoat contamination and can be installed by personnel without technical expertise.

“This system is designed to be applied directly to marginally prepared surfaces, eliminating the need for costly abrasive blasting,” Denso said. “Its high conformability and strong adhesion allow it to encapsulate irregular shapes and profiles, ensuring instant and uniform protection regardless of the underlying substrate,” it said. “The system is UV resistant and capable of encapsulating lead paint, providing an added layer of safety during remediation projects.”

The Covercoat System protects against “acids, alkalis, salts, and other aggressive environmental factors,” the company said. “By enabling application without the need for plant shutdowns, the Covercoat System reduces operational disruptions and delivers significant cost savings over the life of the asset.”

Madison Chemical introduced SPRAY-KAB P-1000, which, the supplier said, removes grease, oil, carbon deposits, and more from engine blocks, transmissions, and machinery components. “Specifically designed for single-stage spray cabinets, this unique formulation contains a precisely balanced blend of surfactants and foam-control agents to clean while prolonging tank life,” Madison Chemical said. “The combination of cleaning efficacy and extended tank life ensures economical results when compared to high-end spray cabinet cleaners.”

Dosage is 2 to 8 oz per gallon at 160° to 180°F. “For heavily soiled parts, longer tank life can be achieved by steam cleaning prior to high-pressure cabinet cleaning, as this keeps more grease and oils from the main tank solution,” the supplier said. “SPRAY-KAB P-1000 is ideal for remanufacturing facilities, industrial machinery repair and rebuilds, equipment re-manufacturing, or anywhere that grease, oil, and carbon deposits need to be completely removed.”

DENIOS introduced the Installation, Maintenance, and Repair Service for the company’s Pop-Up Barriers and asecos cabinets. The offering dedicates technicians, product specialists, documents and resources, and after-sales support staff to services that ensure the spill barriers and battery-storage cabinets stay compliant and operational, the company said.

“From quick downloads and documentation to full-service maintenance programs, replacement parts, and on-site support, DENIOS fully supports their customers,” DENIOS said. “On-site and remote service options are available.”

The service maintains Pop-Up and Spill Barriers and extends their service life. “Through a structured annual safety program, expert technicians check seals for wear, damage, or tears; clean and inspect the sump and barrier structure; replace gaskets at no cost; perform wet testing to activate the barrier; and verify proper automatic deployment and reset function,” the supplier said.

The service also keeps asecos lithium-ion battery storage cabinets “operating safely, efficiently, and in full compliance over time,” DENIOS said. “Regular testing, inspection, and preventive maintenance ensure that critical systems like 90-minute fire resistance, self-closing doors, integrated charging systems, and smoke detection perform as intended. The service helps “keep every component, electrical system, door mechanism, and fire protection features fully functional and ready in case of emergency.” It “transforms asecos cabinets into long-term safety solutions, protecting the facility, people, and operations.”