Magnefast Wear Panels

Elastotec has developed MAGNEFAST™, a unique single sided high performance magnetic attachment system for use in the mining industry.

Based on composites of state-of-the-art ceramics, high strength, high resilience elastomer and mild steel and engineering thermoplastic (ETP) backing plates the Magnefast Wear Panels are precision vacuum moulded. This ensures a rubber tear bond is obtained between the rubber and the ceramic tiles and the rubber and the polymer backing plates. The 100% rubber tear bonding ensures that the ceramic tiles are retained in the panel even under the most arduous operating conditions.

Category:Magnefast Wear Panels Tag:Magnefast Wear Panels

Description

Description

Productivity key features and benefits

Reduce time for installation and replacement.
Reduced number of operators and hours for install / replacement with reduced logistics (accommodation, flights etc.).
Quick and easy rotation of wear position.
No need to access outside of chute with potential working at height and safety issue.
No nuts/ bolts to seize or corrode making removal difficult.
Estimate the risk of damage to wear panels in good condition that can prevent them from being reused. This problem can occur when routable chutes are being reconditioned.
Simple tools for installation and removal of wear panels (rubber hammer, pinch bar).
Reduced time and cost to fabricate new chutes. Can be used in above and below ground applications.
Stable rubber hardness with age.
Resists tile cracking and pull out.
Easy to install.
No holes required in ceramic tiles for single sided attachment. Eliminates potential points of weakness and cracking in the ceramic blocks.
No need for gap between panels to aid fitment panels can be butted up to one another using a rubber hammer so there are NO GAPS. No gaps between wear panels eliminates the possibility of accelerated edge wear due to tracking of material along gaps / recesses.
Multiple magnet fixing locations. Magnet location and number can be varied to suit cut panel shape and size.
Magnets available in a range of champing forces. Wear panel clamping force can be adjusted to suit different applications.
Engineered polymer backing plates. No corrosion. Light weight.

OH&S key features and benefits

Magnetic attachment system key features and benefits

Based on Neodymium, iron and boron composite.
High magnetic force to size ratio.
High resistance to demagnetisation.
Surface plating and stainless-steel housing to provide corrosion resistance.
Stainless steel housing with external thread for ease of installation and removal.
Magnetic attachment eliminates the need for mechanical fasteners.
Magnetic attachment eliminates the need for mounting holes in the substrate.
Low-cost method of attachment.
Magnets operating temperatures up to 120°C.
Magnets available with holding forces of 40Kg/magnet to 100Kg/magnet.

SURFACE TREATMENTS

TYPE	INFORMATION
Metallic	Zinc, Nickel, Nickel + Nickel, Nickel + Tin, Nickel, Gold
Organic	Epoxy, Nickel + Epoxy coating
Temporary	Surface Passivation

Single sided attachment

Ceramic wear panels 100% rubber tear bond backing plate.

Steel wear panels attached to backing plate via plug welding.

Ceramics

Elastotec has formulated a range of wear resistant ceramics. In house ability to test key ceramic properties including Vickers Hardness, Flex Crack Toughness and Wear Resistance has enabled Elastotec to optimise the ceramic performance and confirm these properties on each production batch. Elastotec wear panels can be made in a range of ceramic materials to suit a variety of end use applications.

Property	Amount	Detail
Aluminium oxide AI203	92%	Economic cost with reasonable wear resistance.
Aluminium oxide AI203	96%	Improved wear resistance.
Aluminium oxide AI203	99%	Highest hardness, highest wear resistance grade of aluminium oxide.
Toughened aluminium oxide	ZTA	Aluminium oxide with improved fexural crack resistance - used in applications that require some impact resistance and exceptional wear resistance.
Zoncronium oxide ceramic	YTZ	Combines very good abrasion resistance with exceptional flex crack toughness.

CERAMIC OXIDE PROPERTIES

Typical values

MATERIAL	AL2O3 92%	AL2O3 95-97%	AL2O3 99%	ZTA Toughened Aluminia Oxide	ZIR
Density (g/cc3)	3.6	3.77	3.83	4.1	4.1
Flexural strength (Mpa)	220	300	330	400	400
Impact resistance (Mpa m1/2)	3.7	4.1	4.2	4.5	7.5
Vickers hardness (Hv20)	950	1150	1200	1350	1350
Wear resistance (cm3)	0.25	0.16	0.1	0.05	0.05

Rubber

Elastotec has a strong background and knowledge of elastomers. The elastomer is the lowest cost raw material in a ceramic wear panel but provides critical functions of retention of the ceramic tiles and cushioning from impact. Elastotec has developed a high strength ( >20 Mpa Tensile Strength), high resilience ( >60% resilience) elastomer with in built adhesion promoters. As with the ceramics Elastotec has in house testing capability for all these elastomer physical properties and can guarantee 100% rubber tear bonds between the ceramic and the polymer backing plate for each and every panel.

TYPICAL ELASTOMER PROPERTIES

Typical values

1	2
Tensile strength	20 Mpa
% Elongation	550%
Hardness	55+/-5
Resilience	60%
Abrasion loss DIN53516	100mm3 volume loss

Backing Plates

Elastotec has backing plates available in mild steel and also engineering thermoplastic (ETP). The ETP offers a number of unique features – reduced weight, corrosion resistance, increased impact resistance and reduced cost. For many years the automotive and appliance industries have been using engineering thermoplastics as metal replacements to reduce cost and increase performance. Elastotec is applying this technology to the wear panels it manufactures to provide the same benefits to the mining industry.

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