In mining and materials handling, selecting the correct welding and hard facing process is crucial to combat abrasion and impact wear, observes industrial engineering solutions supplier Weartech.

For on-site work, the company has noted that clients typically rely on flux-cored arc or open-arc welding because it is robust, portable and performs well in harsh environments. In workshop settings, submerged arc welding is preferred for large components, owing to its high deposition rates and consistent quality.

“From a materials perspective, high-impact applications, such as crusher liners, usually require manganese-based alloys that work-harden under impact. For high-abrasion applications, such as chutes or bucket lips, chromium carbide or tungsten carbide systems are more suitable because they resist severe wear,” says Weartech administration coordinator Jabulane Radebe.

He says welding technology plays a central role in extending equipment life in harsh environments, as it enables companies to selectively reinforce high-wear areas using specialised alloys, rather than replacing equipment. This approach can extend service life “several times over” while lowering total cost of ownership.

He notes that tailoring solutions to specific wear challenges – whether abrasion, impact or a combination – is key to maximising the equipment’s life cycle.

“Weartech’s focus is on ensuring that clients get the best performance from their equipment when they are conducting targeted welding and hard-facing strategies, by combining materials expertise with process know-how to help clients reduce downtime and operational costs.”

Meanwhile, Weartech has seen a clear shift towards robotic hard facing over the past decade, driven by consistency, productivity and a global shortage of skilled welders. The shift aligns with broader industry trends searching for efficiency and reliability in harsh operating environments.

“Automated systems deliver highly repeatable results and can run continuously, which significantly improves throughput,” says Radebe.

Manual hard facing, however, remains critical for on-site repairs or irregular components; the industry is, therefore, combining automation with manual processes, depending on the application.

This hybrid approach enables companies to leverage automation’s benefits while maintaining the ability to address more niche repair needs.

Alternatives Gain Ground

Technologies including thermal spray and laser cladding are being used more, as “thermal spray is useful where low heat input is required in corrosion protection or thin coatings, while laser cladding offers very precise, high-quality coatings with minimal dilution, making it ideal for high-value components”, he points out.

While conventional hard facing remains cost-effective for large-scale mining, these technologies serve as complementary solutions instead of competing with each other. Therefore, the choice between traditional welding, thermal spray or laser cladding depends on factors such as component value, operating conditions and cost considerations.

“The priority is making sure the equipment delivers consistent coating quality in the field,” says Radebe.

Clients rely on Weartech’s expertise to maintain equipment performance, especially in critical applications where failure could lead to significant production losses.

Inspection is about ensuring the equipment performs correctly after repair,” says Radebe.

Developing Smarter Solutions

The industry is rapidly evolving, particularly in materials and automation, highlights Radebe.

“We’re seeing more advanced carbide systems and metal matrix composites that offer improved wear resistance without sacrificing toughness,” he notes, adding that high-deposition welding and robotic systems are significantly improving productivity, while modular wear solutions and pre-engineered kits reduce downtime for clients.

The focus remains on delivering longer service life, faster turnaround times and, ultimately, better operational efficiency, and by partnering with equipment suppliers and mining operators, Weartech aims to drive innovation in wear protection.

As mining operations face ongoing pressure to improve efficiency and reduce costs, Weartech’s solutions are positioned to play a key role in maintaining equipment reliability. The company emphasises matching the correct technology to the application – whether it is traditional hard facing, thermal spray or laser cladding – and aims to ensure clients optimise performance and cost, concludes Radebe.