Weir’s materials technology capabilities are a key factor in WARMAN® MCR® slurry pumps remaining the preferred solution for mill circuit applications among the world’s major miners. Notably, Weir’s long-standing expertise in elastomer science enables its rubber-lined pumps to compete directly with, and often outperform, metal-lined alternatives in abrasive slurry applications.
Advanced elastomer development
Mill circuit slurries typically present a challenging wear environment due to wide particle-size distributions and the presence of hard, angular particles. To address this, Weir formulates and manufactures proprietary elastomer compounds engineered for high abrasion resistance, energy absorption, and tear strength. These compounds are developed in-house, allowing precise control over polymer chemistry, filler systems, and curing processes to optimise performance under dynamic slurry loading.
Continuous R&D investment underpins this capability. Weir’s materials scientists and mechanical engineers collaborate to characterise wear mechanisms, refine compound formulations, and validate performance through laboratory testing and field trials. This iterative development cycle ensures that the WARMAN® MCR® pump remains aligned with evolving operational requirements in the mining and minerals processing sector.
Customer-driven engineering
Weir’s engineering teams work directly with mine operators to diagnose wear patterns, understand process variability, and design component solutions that improve pump reliability and reduce total cost of ownership. This collaborative approach supports broader industry goals around sustainability, process efficiency, and operational safety.
The WARMAN® MCR® pump is a direct outcome of this long-term engineering focus, incorporating decades of empirical data, computational modelling, and materials innovation.
Developing wear-resistant alloys
A key advancement in recent years is the expanded use of Armachrome®, a highly wear-resistant overlay material engineered for extreme abrasion environments. Armachrome® wear parts are now applied to critical pump components such as throatbushes, volute liners, and, increasingly, impellers.
The material’s high hardness and superior erosion resistance enable significant extension of component life. Importantly, Weir applies Armachrome® selectively—targeting high-wear zones such as the impeller eye—rather than coating entire components. This precision application reduces material usage while maximising functional benefit.
Field data has demonstrated substantial performance gains. In oil sands operations, Armachrome® components have shown markedly improved wear life compared with white iron. Similar results have been observed in WARMAN® mill circuit pump installations, validating the material’s effectiveness across multiple slurry environments.
Future materials innovation
As the mining industry seeks to reduce energy consumption, extend maintenance intervals, and lower carbon intensity, advanced wear materials will play an increasingly important role. Weir’s ongoing investment in materials R&D—spanning elastomers, overlays, and composite systems—positions the company to deliver solutions that enhance pump efficiency and durability.
Customers are increasingly selecting Weir products not only for performance, but also for their contribution to sustainability objectives, driven by longer wear life, reduced waste, and improved operational efficiency.
