In industrial transmission and conveyor systems, chains serve as core components, and their operational status directly impacts production efficiency and safety. However, the issues of excessive rusting and wear of chains have long plagued various industries, especially in harsh working conditions such as mining, chemical processing, food processing, and ports. A thorough analysis of the underlying causes and the implementation of targeted measures are crucial to ensuring the stable operation of equipment.
1. What are the main causes of chain rusting and wear？
(1) Environmental factors: External inducements for rusting and wear
Humid environments are one of the primary causes of chain corrosion. In high-humidity environments, water vapor and condensed water tend to adhere to the surface of the chain, reacting with oxygen, carbon dioxide, and other gases in the air, thereby accelerating metal oxidation. Especially in coastal or port equipment, salt spray is highly corrosive and can quickly damage the metal structure of the chain, leading to a decrease in strength.
Dust and particulate matter are another key contributor to chain excessive wear. In places such as mines, cement plants, and lime plants, high-hardness dust particles can penetrate the gap between chain pin shafts and sleeves, creating an "abrasive paste" effect that exacerbates mechanical wear. Furthermore, harmful substances such as sulfides and nitrogen oxides contained in the air can form corrosive liquids such as sulfuric acid and nitric acid under the action of condensed water, causing chemical corrosion.
(2) Improper use and maintenance: Human factors exacerbate wear and tear
Insufficient lubrication or improper lubrication methods are common causes of chain wear. Many standard chains rely on regular lubrication to extend their lifespan. In contrast,in industries such as food and pharmaceuticals, the use of lubricants is often restricted to avoid product contamination, leading to rapid wear of chains under dry friction conditions. In addition， if lubrication only remains on the surface and fails to penetrate into key friction areas such as pin shafts and sleeves, it can still exacerbate internal wear.
Improper cleaning and maintenance can also accelerate rusting. If the coal dust, acidic and alkaline substances (such as sugar juice, electroplating solution), and organic juice attached to the surface of the chain are not cleaned in time, they will form corrosive media in a humid environment, continuously eroding the metal surface.
Improper installation and operation can also affect the lifespan of the chain. For instance, insufficient tension can lead to excessive bending of the chain, accelerating fatigue damage; misalignment of the head and tail sprockets can cause eccentric wear; and overload operation can subject the chain to tensile forces beyond its limit, resulting in microcracks or even fracture.
(3) Material and manufacturing quality: fundamental to determining the durability of the chain
The substandard quality of raw materials is the inherent reason for the susceptibility of chains to rust. Some manufacturers, in order to reduce costs, opt for steel with high impurity content and poor corrosion resistance, leading to rusting of the chain in its initial stages of use. High levels of non-metallic impurities in steel, or uneven metallographic structure, can both reduce its corrosion resistance.
The outdated surface treatment process is also a major shortcoming. Without effective galvanizing, nickel plating, or Dacromet treatment, ordinary carbon steel chains are difficult to resist the erosion of complex environments. In contrast, chains that have undergone advanced surface treatment can have their salt spray corrosion resistance improved by 7-10 times, significantly extending their service life.
2. What Are the Targeted Solutions for Chain Rust and Severe Wear?
To address the aforementioned challenges, the industry has developed various mature chain reinforcement technologies, fundamentally enhancing the durability of chains through material upgrades and surface treatment processes.
The adoption of advanced surface treatment technology can significantly enhance corrosion resistance. For instance, nickel plating forms a dense protective layer on the surface of the chain, effectively resisting corrosion from various chemical media, making it suitable for use in industries such as food and packaging. The Dacromet process, based on zinc-aluminum coating, boasts excellent coverage and sacrificial anode protection characteristics, with salt spray corrosion resistance up to several times that of ordinary electroplated chains, making it particularly suitable for high-humidity and marine environments.Our industrial chains support customized nickel plating and Dacromet surface treatment, with salt spray corrosion resistance up to 7-10 times that of standard chains.
Choosing special material chains is a fundamental solution to address corrosion and wear. In situations where corrosive media cannot be avoided or frequent cleaning is required, austenitic stainless steel chains (such as 304 and 316 materials) become the standard choice. Among them, 316 stainless steel, due to the addition of molybdenum, exhibits superior performance in resisting corrosion from chlorides (such as seawater) and strong acids and alkalis, making it suitable for harsher working conditions.We provide 304 and 316 stainless steel chains for different corrosive working conditions, with customizable specifications for mining, chemical and food processing industries.
For scenarios with high wear and special lubrication requirements, there are also dedicated chain products. For example, high-strength wear-resistant chains utilizing special hardening technology and wear-resistant materials can effectively cope with dusty environments. Chains with self-lubricating properties, by embedding solid lubricants in key components such as sleeves, can continuously release a lubricating film during operation, satisfying the need for external lubrication-free operation while ensuring transmission efficiency and longevity.Our self-lubricating chains are engineered for food and pharmaceutical production, achieving lubrication-free operation while ensuring long service life.
Conclusions and Recommendations
The selection of chain types goes far beyond the scope of general "standard parts". Their lifespan and performance are highly dependent on their compatibility with the actual operating environment. Ignoring environmental factors and choosing an inappropriate chain will directly result in ongoing maintenance costs, increased energy consumption, and potential production safety risks.
A correct maintenance strategy is equally crucial. Establishing a regular inspection and lubrication system can promptly identify and mitigate potential issues. For equipment operating in extreme or special environments, it is recommended to consult professional technicians for targeted chain selection and solution design, in order to achieve long-term stable operation of the equipment and optimization of overall costs.For chain selection under extreme operating conditions, it is recommended to consult professional technicians for customized design. If you need a chain solution tailored to a specific environment (such as high temperature, high humidity, strong corrosion), please submit the operating condition information, and we will provide free technical guidance on model selection.
