Plasma Hardfacing Coating Solutions for Mining Coal Cutting Picks – Application Case Study
Mining environments expose coal cutting picks to extreme impact, abrasion, and continuous friction. To improve durability and operational safety, plasma hardfacing has become one of the most effective methods for reinforcing cutting tools used in coal extraction.
At FNS Pipeline Technology Co., Ltd., we specialize in high-performance plasma hardfacing machine solutions. This case study highlights how our DML-series plasma power supply and automated cladding system significantly enhance the performance of mining cutting picks, helping clients reduce costs and improve mining efficiency.
Industry Challenges: Why Cutting Picks Fail
Cutting picks directly contact coal and rock, experiencing intense:
- impact
- friction
- extrusion
- thermal stress
This causes rapid wear, reduced cutting efficiency, frequent pick replacement, and increased safety risks—especially when sparks occur during rock cutting.
FNS Plasma Hardfacing Solution
To address these issues, FNS Pipeline Technology Co., Ltd. applied a tailored plasma hardfacing coating process using the DML plasma power source and PLC-controlled automatic welding equipment. This ensures consistent coating quality and optimal metallurgy bonding between substrate and wear-resistant layer.
The hardfacing layer uses:
- high-hardness metal-ceramic composite powder
- precisely controlled heat input
- low dilution rate plasma arc welding parameters
The result is a uniform, dense and highly wear-resistant coating on the cutting pick head.
Key Performance Improvements After Plasma Hardfacing
1. Dramatically Enhanced Wear Resistance
The plasma hardfacing coating forms a high-hardness ceramic-metal layer on the cutting pick tip. This layer provides:
- excellent hardness
- strong toughness
- superior resistance to abrasion and impact
The reinforced coating slows down wear on the pick body and ensures synchronized wear between the steel body and carbide tip-significantly extending the service life of mining cutting picks.
2. Stronger Bending Resistance
Using ANSYS simulation, FNS engineers analyzed stress distribution and failure modes during cutting operations. Based on this data, we refined:
- heat-treatment procedures
- forming steps
- machining processes
The result:
- improved overall bending strength
- higher surface hardness at the pick shank
- reduced risk of deformation or breakage during deep cutting operations
3. “No-Spark” Safety Benefit
Traditional picks generate bright sparks-especially when cutting rock-posing safety risks underground.
After applying the plasma hardfacing coating, sparks are reduced by over 90%.
Grinding test comparison:
- Standard pick: bright, divergent sparks ≈60 cm long
- Plasma hardfaced pick: faint, minimal sparks ≈10–20 cm
This dramatically improves safety in coal mines where spark generation is strictly controlled.
Advantages of FNS Plasma-Reinforced Cutting Picks
FNS hardfaced cutting picks offer:
- significantly improved wear resistance
- longer service life
- reduced breakage
- near “no-spark” operation
- lower maintenance and replacement costs
- enhanced mining productivity
With advanced plasma welding equipment, the coating composition and geometry can be tailored for different coal and rock conditions. Additionally, plasma hardfacing eliminates the softening problems caused by traditional brazing processes.
Reliable Plasma Hardfacing Technology From FNS
The plasma hardfacing solution provided by FNS Pipeline Technology Co., Ltd. has proven highly effective for mining coal cutting picks. Through advanced plasma welding equipment, high-performance metal-ceramic powders, and automated processing, FNS continues to help customers achieve safer, more efficient and more economical mining operations.
For cutting picks, conveyor components, middle troughs, mining teeth, and other wear-exposed mechanical parts, FNS offers complete plasma hardfacing solutions and customized technical support.
