Biggest Performance Challenges That Mining Equipment Face

In the mining industry, equipment failure could mean a number of things – none of them pleasant. When equipment fails, downtime is experienced. Whether parts need to be replaced or repaired, it’s going to take time and money. This is detrimental to the bottom line of any company, but particularly in mining. Possibly more importantly, however, equipment failure can mean something far more crucial. It can be a safety hazard. And anytime that lives are endangered more than is already necessary, it is never considered a positive development.

There are three things that present the biggest challenge to mining equipment. Fortunately, using a thermal spray company to apply the appropriate coatings to parts and components can make all the difference in the world. Let’s explore these challenges and explore how thermal coating can make or break your bottom line and safety record.


Wear and abrasion are very closely related in so much that they are caused by many of the same situations, and they are treated with similar coatings and processes. Parts that are commonly plagued by wear and abrasion issues are as follows (though all may not apply to the mining industry):

  • Agitators
  • Valves
  • Roll Surfaces
  • Mixers
  • Pumps
  • Plates
  • Winders

When diagnosing an abrasion or wear problem, in order to identify the appropriate coating, it is essential to have a full understanding of the various types of wear. Some identifiable wear mechanisms are as follows:

  • Adhesive
  • Fretting
  • Erosive
  • Abrasive


The good news is that it is possible to achieve abrasion and wear resistance through the proper thermal spray coating process. The following are a number of abrasion and wear resistant coatings most typically used:

  • Aluminum Oxide Ceramic –a.k.a. white aluminum, this product is capable of resisting erosion, even in excessively high temperatures, as well as resisting wear by threads and fibers when applied as a dense coating.
  • Chrome Oxide Ceramic – these self-mating, anti-galling coatings are used due to their superb wear resistance. In particular, they protect against abrasive grains, hard surfaces, cavitation, and particle erosion under 540C.
  • Tungsten Carbide – when it comes to wear resistant materials, this is one of the most effective. It can be applied through the HVOF or plasma spray process. It is ideal for replacing hard chrome plating because it can be polished to a mirror finish. As a bonus, these coatings are capable of achieving incredible levels of hardness.


No matter the environment or the industry, the structural integrity of parts and equipment is forever being reduced or destroyed by the pervasive problem of component corrosion. Whether it is corrosive chemicals launching a high rate of chemical attack or as simple as the rusting of steel left out in the elements, corrosion can devastate an operation. Protective coatings seal the surface and protect against corrosion, no matter the cause.

If you have been searching for just the right thermal spray company to apply the appropriate coatings to your mining equipment, look no further. A&A Coatings has been servicing industries for more than 70 years. We can help you with all of your mining equipment thermal spray needs. Contact us today to find out how A&A Coatings can be of assistance to you and your company.

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