Plasma Cladding Solutions for Hydraulic Supports: Enhanced Wear Protection for Mining Equipment

Hydraulic supports are critical structural components in modern longwall mining. Their function is to maintain roof stability and ensure safe coal extraction under extreme underground conditions. However, the combination of high humidity, acidic corrosion, abrasive particulate matter, and heavy mechanical loads often leads to rapid degradation of the support’s surface coating and base metal-eventually causing seal failure, load-bearing instability, and significant safety risks.

To address these challenges, FNS Pipeline Technology Co., Ltd. provides an advanced plasma cladding solution tailored specifically for hydraulic supports, offering a robust surface reinforcement method that dramatically improves equipment durability and operational safety.

1. Challenges in Hydraulic Support Operation

Underground mining environments present several issues:

• Acidic and corrosive atmosphere that erodes standard coatings

• High humidity leading to micro-pitting and rust-induced seal failures

• Heavy cyclic loads accelerating wear on the cylinder, piston rod, and jacks

• Surface damage on the base metal, compromising load capacity and sealing integrity

Without adequate surface protection, hydraulic supports become vulnerable to deformation, leakage, and catastrophic failure-jeopardizing both safety and production efficiency.

2. FNS’s Plasma Cladding Solution for Hydraulic Supports

With more than a decade of experience in metal remanufacturing, FNS Pipeline Technology Co., Ltd. recommends a PLC-controlled plasma cladding system combined with high-performance alloy powders to restore and strengthen the surface of hydraulic support components.

Key features of the FNS plasma cladding solution:

• Low dilution rate, ensuring excellent bonding with minimal thermal impact

• Concentrated heat source, achieving precise melt pools and uniform coating

• Enhanced metallurgical structure, improving resistance to wear, corrosion, and impact

• High automation, reducing labor cost and ensuring consistent quality

By applying Stellite alloy powder (cobalt-based) or tungsten carbide alloy powder, the cladded layer becomes significantly more durable than the original base metal—ideal for mining environments.

3. Recommended Equipment: FNS Plasma Cladding System

FNS offers a full solution for hydraulic support cladding, including:

1) Plasma Power Supply

• FNS DML-VO3BD plasma power source
  Suitable for heavy-duty industrial cladding
  Stable arc performance and low operational cost

Customers with specific requirements may contact FNS for customized equipment selection.

2) PLC Automated Control System

• Smooth torch motion

• High repeatability

• Aesthetic and uniform cladding appearance

• Fully customizable based on component size and production demands

This automation platform drastically reduces manual error while improving productivity and coating stability.

4. Plasma Cladding Workflow for Hydraulic Supports

FNS follows a standardized and reliable process to ensure coating quality:

1. Component selection and engineering design

2. Surface cleaning (rust, oil, and contaminants)

3. Plasma cladding with selected alloy powder

4. Non-destructive testing (NDT)

5. Defect repair (if needed)

6. Machining and polishing to final dimensions

The resulting surface layer is smooth, dense, and tightly bonded—ready for long-term use in harsh working conditions.

5. Performance and Application Benefits

Hydraulic supports treated with FNS plasma cladding exhibit:

• Superior wear resistance

• High corrosion resistance in acidic mine atmospheres

• Increased impact tolerance

• Extended service life, reducing downtime and replacement costs

• Stable sealing performance even under heavy loads

Plasma cladding is also an environmentally friendly and energy-efficient process, supporting green manufacturing and sustainable industrial development.

Beyond hydraulic supports, FNS’s plasma cladding solutions are widely applied to mining components such as:

• Cutting picks

• Middle troughs

• Sliding shoes

• Chain conveyors

• And other wear-intensive parts

With deep industry expertise and advanced plasma cladding technology, FNS Pipeline Technology Co., Ltd. provides mining companies with a proven method to enhance the performance and longevity of hydraulic supports. By reinforcing the surface with high-strength alloy coatings, we help improve safety, reliability, and economic efficiency in demanding underground operations.

For customized plasma cladding systems and complete mining repair solutions, FNS is ready to support your needs.