Many engineers rely on metallic materials when designing custom-machined structural and wear components. However, this choice often does not suit the specific needs of steel and aluminum mills, which frequently face uptime and maintenance costs as core pain points. Ryertex HDA was created specifically to solve these concerns in rolling mills.
Machined polymers and composites offer a superior alternative, providing high-strength and durability for producing precision-machined parts. Ryertex HDA is a high-density, abrasion-resistant grade material that offers distinct advantages over conventional metal materials, delivering optimal part performance.
The Hidden Cost of Traditional Metallic Wear Parts
Metallic wear parts are vulnerable to the following factors, making the Total Cost of Ownership (TCO) considerably higher:
- Corrosion
- Frequent replacement
- Wear-induced friction
- Wear on mating parts
- External lubrication is required
While the upfront cost of traditional metallic wear parts may seem low, hidden costs, such as labor, downtime, and inefficiency, often far exceed the initial purchase price.
Analyzing the Financial Impact of Downtime
Maintenance, Repair, and Overhaul (MRO) downtime can lead to significant unexpected expenditures that can severely impact financial performance through:
- Direct repairs and/or replacements
- Emergency labor requirements
- Expedited parts and shipping
- Inventory carrying costs
- Lost revenue/production
Premature failure of equipment due to unreliable metal parts and poor maintenance can limit the total Return on Investment (ROI) and reduce customer confidence, negatively impacting a company’s bottom line and reputation.
Common Failure Modes of Bronze and Steel Components in Mill Environments
Steel components often experience fatigue and brittle fracture due to thermal stresses or high loads. Bronze components used in gears or bearings often fail due to fatigue, galling, or erosion caused by poor lubrication, particularly in high-load, slow-speed scenarios.
Common failures for both materials include:
- Abrasive wear
- Corrosion
- Fatigue
- Galling (adhesive wear)
- Overload
- Lubrication failure
The Challenge of Lubrication and Maintenance Cycles in High-Heat Areas
Maintaining proper lubrication and maintenance cycles of metallic wear parts in high-heat areas can be difficult due to the following challenges:
- Accelerated thermal oxidation
- Increased leakage
- Lubricant degradation
- Reduced viscosity
- Thermal cracking
- Neglect
Introducing Ryertex HDA: A High-Density Thermoset Solution
Ryertex® HDA (Heavy Duty/Alumina) is a phenolic laminate composite that features a homogenous construction for optimal part performance. The durable material consists of several plies of heavyweight canvas cloth, which has been saturated twice with phenolic resin and then modified with alumina to add hardness, increase wear resistance, and extend bearing wear without seizing to metal shafts.
What Distinguishes Ryertex HDA Grades From Standard Phenolics
Unlike thermoset plastic components (standard phenolics) that are made from layers of fabric or paper saturated in phenol-formaldehyde resin, the material composition of Ryertex HDA offers a far superior coefficient of thermal expansion and load-bearing capacity.
The key distinctions between standard phenolics and Ryertex HDA include:
- Alumina modification
- Reinforcement materials
- Seizing resistance to metal shafts
- Structural integrity
- Thermal expansion
- Visual inspection (red material color)
Why Thermosets Are Superior to Thermoplastics for High-Load Mill Applications
Thermosets are the preferred choice for high-temperature, high-load mill applications due to the following properties:
- Creep resistance
- Cross-linked
- Dimensional stability
- Irreversible molecular structure
- Superior stiffness
Thermoplastics often soften under stress and heat. Unlike thermosets, thermoplastics are unable to resist abrasion, withstand chemical exposure, or maintain their structural integrity. This makes thermosets the better option for heavy-duty industrial components used in high-load mill applications.
Key Technical Specifications of Ryertex HDA
The Technical Data Bulletin explains the typical properties of Ryertex HDA, which include:
- Compressive Strength: 36,500 psi
- Maximum Operating Temperature: 125 ºC
- Specific Gravity: Between 1.40 and 1.42, density relative to water
Benefits of Ryertex HDA for Mill Applications
With a coefficient of thermal expansion that closely resembles metal shafts, Ryertex® HDA is an ideal material choice for high-load, high-demand mill applications, offering the following benefits:
- Excellent wear resistance
- Exceptional impact resistance
- Significant reduction in friction and energy consumption
- Superior load-bearing properties
Coefficient of Friction (CoF) Comparison: Ryertex vs. Bronze/Steel
Ryertex HDA typically offers exceptional wear resistance and a more consistent, lower coefficient of friction (CoF) compared to traditional bronze/steel materials.
Corrosion and Chemical Resistance in Quench and Cooling Zones
These properties are essential for preventing premature material failure and maintaining system integrity in quenching and cooling zones, commonly found in industrial cooling systems that undergo constant temperature changes and chemical exposure.
Weight Reduction
Ryertex HDA is an excellent alternative to metal bearings in mill applications, providing a high-performance, lightweight option that enhances wear resistance and reduces inertia. The reduced weight offers easier handling, prevents shaft seizing, and reduces undue stress on machinery.
Applications of Ryertex HDA in Steel and Aluminum Processing
Applications include:
- Bearing and bushings for material handling systems
- Machines wear pads, slide plates, and shims
- Roll neck bearings and thrust collars (continuous casters)
Contact WS Hampshire, Inc. To Learn More
As a full-service fabricator and supplier of non-metallic materials, WS Hampshire, Inc. offers innovative solutions for challenging applications across a broad range of industries.
Contact us today to discover how replacing metal wear parts in your steel/aluminum mill application with Ryertex HDA can optimize the performance and reliability of critical components.