Our customers’ results validate AIM’s technical capabilities and real-world value.
Case1
Built to Last:
“Bone-Skin-Muscle” Crusher Tooth Redefines Performance Under Pressure
The Challenge
Crusher tooth operates under extreme conditions—facing constant impact, abrasion, and crushing cycles. In demanding environments like oil sands and hard rock mining, traditional teeth often wear out in weeks, leading to:
● Frequent unplanned downtime
● High maintenance costs
● Reduced reliability and efficiency
Our Solution: The “Bone-Skin-Muscle” Design
To address this challenge, AIM developed a revolutionary solution: the?“Bone-Skin-Muscle” crusher tooth?— a multi-material design concept that targets wear and impact resistance at every level.
Bone – Load-Bearing Backbone
The body of the tooth is reinforced with sintered Titanium Carbide (TiC) or Tungsten Carbide (WC). These materials are selected for their exceptional fracture toughness and impact resistance.
Skin – Maximum Wear Resistance
The outer layer of the tooth is made from Chrome White Iron (CWI) or PTA-welded Tungsten Carbide overlay, both known for their outstanding hardness and sliding wear resistance. This outer “armor” shields the carbide backbone from direct abrasion.
Muscle – Engineered Core Strength
The base or shaft of the tooth is made from a high-strength casting alloy, designed to absorb high loads and resist deformation. This “muscle” provides the strength to keep the structure integrity during crushing.
Advanced Manufacturing: Precision-Cast, Fully Bonded
Unlike traditional brazing or clamped-on tips, AIM’s crusher teeth are produced through a precision casting process.
● Sintered carbide inserts are pre-positioned within the mold
● Molten Chrome White Iron and alloy steel are then poured in sequence
● During cooling, the three zones metallurgically bond into one integrated structure
This process eliminates the risk of mechanical failure, such as cracking, loosening, or stud drop-out. The result is a rugged, unified wear part with no weak points — even in thermally or mechanically stressful environments.
Field-Proven Performance
AIM’s “Bone-Skin-Muscle” teeth have been deployed and tested in some of the harsh mining conditions — including oil sands operations in Canada and hard rock mines globally.
Customers have reported:
● Extended wear life by 2-3 times
● Reduced replacement frequency
● Lower overall maintenance costs
Case2
Redefining Durability:
The Success Story of our Crack Free Chrome Carbide Overlay (CCO) Plates
Delve into the extraordinary success story of our Chrome Carbide Overlay (CCO) plates, where cutting-edge technology and proprietary treatments converge to set new standards in wear solutions. Beyond mere goals, Canadian Innovative Materials has achieved an unparalleled feat in enhancing the performance of CCO plates through advanced automatic welding technology and post-weld heat treatment.
Advanced Technology and Proprietary Treatment:
At the core of our achievement lies our ability to produce CCO plates up to 25 mm thick in a single pass, thanks to our advanced automatic welding technology (modified sub arc welding). A proprietary post-weld heat treatment ensures a never-before-seen smooth overlay surface, free of check cracks and underbed cracking.
Versatility in Cutting and Repair:
Our CCO plates offer unprecedented versatility. Whether cut by flame, PTA, or laser, and repaired using typical CCO wires such as Arctec 661T and W1063, these plates showcase adaptability that goes beyond industry standards.
The Challenge: Enhancing Pump Box Wear Life
The application of AIM CCO plates in a high-wear pump box area exemplifies the transformative impact of our technology. Facing accelerated wear and cracking with the original CCO plates, the operator sought AIM's assistance to increase the wear life.
Our Solution: 20mm Crack-Free CCO
Responding to the challenge, Canadian Innovative Materials delivered a groundbreaking solution - a 20mm CCO crack-free overlay with a smooth surface. The result was not just a repair but a transformation of the wear dynamics in the pump box area.
Operator Testimony: Simple, Effective, and Fracture-Free Repair
The operator's testimony speaks volumes. The repair process, once seen as a challenge, became simple and highly effective with AIM's crack-free CCO plates. The ease of cutting and welding further added to the operator's satisfaction. Post-repair, no fractures or cracks were observed, validating the durability of our CCO plates.
Trial: Impressive Results
A year-long trial at a major oilsands operator (40 million tonnes) showcased the longevity and wear performance of AIM's crack-free CCO plates. AIM Plate’s thickness of 12+20 mm saw an overall wear rate of 2-3 mm/year, a stark contrast to the traditional CCO plate's wear rate of 10-12 mm/year in the exact same location.
Operator Satisfaction and Future Prospects:
With an overall highly satisfied operator and successful trial completion, Canadian Innovative Materials has not only met but exceeded expectations. The operator is now inclined to utilize AIM's CCO plates moving forward, reinforcing the credibility and impact of our wear solutions in challenging operational environments.
After two years of operation, the CCO plate still stands strong.
Case3
Revolutionizing Oilsands Industry:
The Success Story of Titanium Carbide Reinforced Chrome White Iron (TiC CWI) Suction Liners
Canadian Innovative Materials takes pride in introducing a game-changing development in wear solutions – the Titanium Carbide Reinforced Chrome White Iron (TiC CWI) suction liners. Dive into the details of our innovative manufacturing process and the exceptional success achieved in the oilsands industry
Innovative Manufacturing Process:
Our TiC CWI suction liners are born from a precision manufacturing process. Titanium powder and carbon fiber are meticulously compacted and pre-formed in the mold cavity. The infusion of molten metal triggers the ignition of Titanium (Ti) and Carbon (C), resulting in a suction liner that not only outperforms conventional CWI but is also 20% lighter.
The Challenge: Doubling TSRU Suction Liner Wear Life
Facing a critical challenge in the oilsands industry, Canadian Innovative Materials committed to doubling the wear life of Large Oilsands Company's TSRU suction liners. The existing OEM Liners were only reaching 2190 hours – a hurdle we were determined to overcome.
Exploration and Trials:
In the pursuit of longevity, we explored Titanium Carbide (TiC) suction liners. The trials unveiled TiC as the standout performer, showcasing a substantial improvement in wear life compared to OEM suction liners.
AIM Suction Liner - TiC Reinforced CWI.
AIM TiC CWI Suction Liner after 4600 hours
OEM Suction Liner after 2190 hours
Triumph of Titanium Carbide:
The rigorous testing and analysis demonstrated the superiority of TiC suction liners, prompting us to implement the upgrade. The outcome exceeded expectations, successfully doubling the wear life of TSRU suction liners and setting a new standard in the industry.
With OEM suction liners capping at 2190 run hours, our TiC suction liners are projected to reach an impressive 6000 hours. This projection signals not just longevity but a paradigm shift in wear solutions for the oilsands industry.
Competitive Pricing and Cost Efficiency:
Canadian Innovative Materials understands the importance of cost efficiency. Our TiC suction liners not only outperform OEM counterparts but are also competitively priced, pr oviding a more than 2.5x return on investment compared to OEM products.
Conclusion:
The success of TiC CWI suction liners is not just a milestone for Canadian Innovative Materials; it's a testament to our commitment to innovation and excellence. The results have also expanded onto other wear assets such as beam caps and spool inserts. As we continue to refine and redefine industry standards, the TiC technology stands as a beacon of progress, offering unparalleled durability and cost-effectiveness in the demanding oilsands environment.
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