Ador Fontech — Hardfacing & Wear-Resistant Solutions

Ador Fontech is the wear-resistance and hardfacing-solutions sub-brand of Ador Welding Limited. While Ador Welding focuses on general welding consumables (electrodes, wires, machines), Ador Fontech focuses specifically on solutions to extend equipment service life in abrasive, impact-loaded, or corrosive environments — primarily for cement plants, steel plants, mining operators and bulk-material handling. Ador Fontech products include hardfacing electrodes (Zedalloy), flux-cored hardfacing wires, wear plates, ceramic-lined pipes, and engineered wear-protection consultancy.

Hardfacing is cost-effective when the worn part is large, expensive, or has a long lead time. Examples: cement-mill rollers (₹15-50 lakh new vs ₹2-5 lakh for re-build), mining bucket teeth (1 day re-build vs 4-week new-part lead time), conveyor-pulley relagging (₹50k vs ₹3 lakh for new pulley). Rule of thumb: if the component costs more than ₹50k new and the wear is on a defined surface area (not full-body), hardfacing is usually 4-10× cheaper than replacement and extends service life by another 60-150%.

Zedalloy hardfacing electrodes and FCW wires are used widely across the Andhra Pradesh cement corridor and by pan-India cement majors. Typical application: kiln girth-gear & pinion build-up, VRM table-segment & roller re-build, crusher hammer-tip hardfacing, raw-mill liner protection. We supply directly to plant maintenance teams or via cement-OEM service contractors.

VRM rollers: Zedalloy 600 at 58 HRc (600 BHN) single layer on the wear face, over a Zedalloy 350 build-up at 35–40 HRc — balance hardness with toughness so the deposit doesn't crack. Crusher hammers: Zedalloy 550 at 54–56 HRc (540–580 BHN) over three layers, or Zedalloy 600 where abrasion dominates over impact. For severe abrasion with low impact (slurry-pump impellers, screw augers): a tungsten-carbide-bearing deposit — Ador's self-shielded O-7075 open-arc wire — hardest but most brittle. Ador do not publish a hardness figure for O-7075, so we quote it from the current datasheet.

For new chutes, hoppers, cyclones, and dust-collector internals where the wear surface is large and accessible at fabrication time, pre-hardfaced wear plates (Zedalloy weld-overlay clad) are usually faster and lower total cost than in-situ hardfacing. The factory deposit is more uniform and the labour saving on installation is significant. For repair work on existing equipment in-situ, especially on irregular geometries (gear teeth, bucket teeth, hammer tips), in-situ stick-electrode hardfacing is the right choice.

Yes. Ceramic-lined pipes (alumina-92% bonded into mild-steel pipe) are stocked in 4", 6", 8", 10", 12" diameters with matched elbows (45°, 90° bends). Used for ash slurry, coal slurry, alumina, bauxite, cement-clinker pneumatic conveying. Service life 5-15× plain mild steel — single ceramic-lined elbow can last 10+ years vs 6-12 months for plain steel in the same duty. Engineered project work for power plants, alumina refineries, cement plants, mineral-processing operations.

Yes. Ador Fontech supports field application of hardfacing — pre-application surface preparation guidance, electrode/wire/parameter recommendations, build-up sequencing, post-deposition cooling protocols. For new applications or unfamiliar wear environments, we conduct a wear-mode survey (abrasion, impact, corrosion, temperature) and recommend the right deposit chemistry. Site engineering guidance is included with rate-contract supply at no additional cost.