In fracking, frac plungers are essential components that endure harsh abrasive and corrosive environments. These plungers are subject to intense wear due to friction, high-pressure fluids, and exposure to chemicals. To extend their operational life and reduce maintenance costs, advanced coatings are needed. Kennametal Stellite’s Deloro 60 Alloy offers an effective solution to enhance the durability and longevity of frac plungers.
Extending Frac Plunger Life with the Kennametal Stellite™ Deloro 60 Alloy
Introducing High-Performance Materials for Extreme Conditions
Deloro Alloys are a range of nickel-based materials known for their exceptional hardness, wear resistance, and corrosion resistance. These alloys are formulated with additional elements such as chromium (Cr), carbon (C), boron (B), iron (Fe), and silicon (Si), which contribute to their ability to withstand some of the toughest industrial environments.
These alloys can be tailored to various hardness levels, ranging from 15 to 60 HRC, offering flexibility from softer, machinable grades to extremely hard, wear-resistant formulations. Their unique microstructure—comprising Ni-solid solution, Ni₃B, Cr₅B₃, Cr₂B, CrB hard phases, and other chromium carbides—provides exceptional strength and wear resistance, making them ideal for coating components exposed to abrasive or corrosive conditions.
Deloro Alloys are particularly effective in applications that demand both toughness and hardness. The inclusion of silicon and boron in their composition gives Deloro Alloys self-fluxing properties, and their low melting points make them highly versatile for spray/fuse, powder, and rod/wire welding applications. Furthermore, Deloro Alloys offer high oxidation resistance and can maintain performance at temperatures up to 600°F, ensuring robust protection for a wide range of industrial components.
3D Rendering of a Frac Plunger
The Ideal Solution for Frac Plungers
Among the Deloro Alloys, Deloro 60 stands out as an ideal solution for enhancing the performance and lifespan of frac plungers. This nickel-based alloy offers exceptional wear resistance, hardness, and corrosion resistance, making it the perfect choice for components exposed to the extreme conditions found in fracking operations.
While Deloro 60 is not machinable, it can be ground to achieve the desired surface finish. Additionally, it offers superior fusing characteristics, making it highly effective for coating applications. The fusion of Deloro 60 coatings can be achieved using methods such as oxy-fuel torch, induction heating, or furnace fusion, ensuring durable, high-performance coatings that extend the life of critical components.
The combination of high hardness, wear resistance, and corrosion resistance allows Deloro 60 to significantly extend the service life of frac plungers, reducing the need for frequent replacements and minimizing costly downtime in fracking operations.
Deloro 60 (as-cast) Microstructure, 500x
Applications of Deloro 60 Alloy
While Deloro 60 is particularly beneficial for frac plungers, its versatile properties make it suitable for other high-wear applications across various industries. Some common uses include:
- Wire Drawing Capstans
- Pump Components: Casings, Impellers, Plungers, Sleeves, and Shafts
- Mechanical Seal Faces
- Feed Screws
- Centrifuge Screws
- Bushings
- Plastic Molding Components
- Glass Molding Components
- Chemical Processing Valves
- Petroleum Processing Valves
Nominal Composition (Mass %) and Physical Properties
| Ni | Cr | Si | Fe | C | B | Hardness | Density (deposit) | Melting Range |
| Base | 14-15 | 2.0-4.5 | 3-5 | 0.7 | 3.2 | 56-64 HRC | 7.8 g/cm3 0.282 lb/in3 | 906-1081ºC 1663-1978ºF |
Summary
By applying Deloro 60 to frac plungers, fracking operators can significantly extend the life of their equipment, reduce maintenance costs, and improve operational efficiency. The exceptional hardness, wear resistance, and corrosion resistance of Deloro 60 make it the ideal choice for components exposed to the harshest conditions. Whether used for frac plungers or other critical industrial parts, Kennametal Stellite’s Deloro 60 Alloy ensures durability and longevity, making it a smart investment for industries demanding high-performance materials.