In industrial material handling, the choice of chain often dictates the functionality and durability of the entire conveyor system. Especially in hot and abrasive conditions, such as in metal processing and the steel industry, return loop chains offer significant advantages compared to ordinary chains. The correct chain selection can reduce maintenance needs, extend service life, and improve overall process efficiency. Discover the features of forged link conveyor chains and clarify why they are a popular choice in demanding bulk material applications.
Maintenance managers often face situations where conveyor chains wear out faster than expected. The cause is rarely solely the material itself, but rather the overall picture: temperature control, load distribution, and the correct chain type for the operating conditions.
Mikä on takolenkkiketju ja miten se eroaa tavallisesta ketjusta?
A forged link chain is a specially manufactured conveyor chain where the links are forged from a single piece of steel instead of having a standard welded construction. The forging process refines the steel's structure and eliminates internal weaknesses, making the chain significantly more durable for heavy-duty use.
A standard conveyor chain is usually made by welding or assembling several parts. This manufacturing method leaves structural weaknesses, such as welds or joints, which can break under load. In a drop forged chain, each link is a single, solid piece without internal weaknesses.
In material selection, towing link chains often utilise special steels, such as boron steel. Boron steel better retains its mechanical properties at high temperatures compared to ordinary manganese steel. For example, at a temperature of 400 °C, the hardness of a boron steel chain link can be up to 70 % higher than that of a manganese steel one.
Why does a roller chain have better durability in heavy use?
The forged chain is more durable in heavy-duty use due to three key factors: a uniform structure, better material, and higher breaking strength. The forging process allows for even load distribution in the links and eliminates internal stress concentrations.
A structural advantage arises from the fact that a forged link does not contain weld seams or other weaknesses. When the conveyor is subjected to impact loads, such as large material build-ups, a forged link chain distributes the load more evenly throughout the structure. A standard chain can break at its weakest point, such as a weld seam.
In terms of material, the boron steel tow link chain is heat-treated to through-harden, making it tough and wear-resistant. Surface hardness does not change with wear, unlike manganese steel, which only surface hardens. This means even wear and a longer service life.
At high temperatures, the difference becomes even more pronounced. While a standard chain rapidly loses its tensile strength as the temperature rises, a boron steel forged link chain retains its properties even at temperatures of 400°C. This is critical in applications such as heat recovery boilers in smelters and gas cooling conveyors.
When should you choose a lifting chain instead of a standard chain?
A link chain is recommended when the operating temperature exceeds 200 °C, the material is particularly abrasive, or the conveyor is subjected to impact loads. Particularly in metal processing, the steel industry, and foundries, a link chain is often the only durable solution.
The temperature criteria are clear: if the continuous operating temperature exceeds 200°C, a standard chain will not last long. A return loop chain operates reliably at temperatures of 300–400°C, making it a suitable choice for hot processes. At temperatures below 200°C, a basic solution may suffice if other conditions are not particularly demanding.
Durability is the decisive factor in chain selection, particularly when the material being conveyed contains abrasive particles or large accumulations. Tailormade forged conveyor chains distribute impact loads better and withstand mechanical stress for longer than standard chains.
From an economic perspective, a lubricated roller chain costs more to purchase, but its extended lifespan and reduced maintenance requirements make it a worthwhile investment in demanding conditions. Typically, the service life can be double or even triple that of a standard chain in hot and abrasive applications.
Maintenance managers should consider a rear loop chain, especially if current chains are wearing out faster than expected or causing production downtime. Investing in a better chain can save significant amounts of money in the long run due to reduced maintenance and a longer service life. Contact us to determine if a return roller chain is suitable for your process and what kind of savings it could bring.
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