Chromium Carbide Overlay (CCO) Wear Plate - WALDUN

Chromium Carbide Overlay (CCO) Wear Plate - WALDUN

Chromium Carbide Overlay (CCO) wear plates are recognized in various industries for their exceptional wear resistance and durability. According to recent industry resources, CCO wear plates are composed of a base material that is encrusted with a layer of chromium carbide, making them ideal for high-abrasion environments.

FAQ 

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What is the Hardness of the Chromium Carbide Plate?

Chrome carbide plate welding layers are engineered for extreme hardness.

Typically, surface hardness can reach HRC 58 to 62, while micro hardness can surpass HV 700.

What is the Flatness of Chromium Carbide Plate?

The recommended flatness for chromium carbide plates should be maintained within ±3 mm per meter.

At Waldun, our advanced welding techniques meticulously control welding deformation, ensuring minimum distortion.

Furthermore, post-welding, we employ a leveling machine to achieve precise flatness. Our overlay plates meet stringent industry standards even without additional leveling.

How to Cut to the Length of the Chromium Carbide Plate?

It is entirely possible to obtain custom lengths for your chromium carbide plate.

The most common method is plasma cutting, which is highly effective. Alternatively, water jet cutting and high-powered lasers are also viable options.

How do you Weld Stud on Chromium Carbide Plates?

Linking chromium carbide plates to other components involves stud welding.

This method uses a welding torch to attach the stud to the plate's surface, initiating the arc weld as one end of the stud contacts the plate.

What Kind of Chromium Carbide Overlay Plate is more Suitable for Acid Environments?

A range of chromium carbide plate types can effectively withstand harsh acidic environments.

Choosing plates with higher carbon content is recommended for optimal performance.

What Standards are required for Chromium Carbide Plates?

Standards for chromium carbide plates vary by country.

Waldun holds certifications in compliance with Asian, American, European, and Australian standards. You can verify our certifications when placing your order with us!

What Powders can be Used for Welding Chromium Carbide Plates?

A diverse array of powders can be used for welding chromium carbide plates.

Options range from atomized iron welding powders to sponge iron powders, depending on your specific needs.

Where Can You Find the most effective Chromium carbide overlay plates?

There is a plethora of manufacturers and vendors for chromium carbide overlay plates in the market. However, Waldun is regarded as a premier and reliable source.

Specializing in wear plates since our inception, we continually strive to enhance the quality of our chromium carbide overlay plates for our customers.

Why Trust WALDUN For Your Chromium carbide overlay plate?

Our chromium carbide overlay plates are thoughtfully designed and refined, taking into account feedback from each client interaction. The cutting-edge equipment we employ is also manufactured in-house.

With experience collaborating with diverse businesses, you can count on us for your chromium carbide plate needs. Expect delivery within 20 days of placing your order.

Additionally, we provide samples for you to evaluate whether they meet your specifications! When you choose Waldun for your chromium carbide plate requirements, you will not be disappointed!

How long is the delivery time of chromium carbide overlay plate?

Typically, the delivery timeframe is 5-10 days if the goods are in stock, or 15-25 days if they are not, depending on the quantity ordered.

Can I get a free sample of chromium carbide overlay plate?

Yes, free samples are available upon request.

What are the payment terms of chromium carbide overlay plate?

We accept payments via TT or LC. If you have a reliable credit history, we can consider OA as well.

Can I get after-sales service if I buy chromium carbide overlay plate?

WALDUN boasts a dedicated after-sales service team equipped to address customer concerns promptly. In case of any quality issues, a responsible representative will provide reasonable solutions within 12 hours of notification.

Where Can You Buy Chromium Carbide Overlay Plates?

You can acquire chromium carbide plates from numerous suppliers worldwide. However, for the highest quality, Waldun is your best option, as we are rapidly emerging as a leading provider of hardfacing and wear plates in the region. You can depend on us!

What Should You Consider Before Buying a Chromium carbide overlay plate?

Experts recommend evaluating several factors before purchasing a chromium carbide overlay plate, including:

• Chemistry of the Chromium carbide overlay plate

Different chemistries in chromium carbide plates can enhance or inhibit the performance of your workpiece. Focus on chemistries that will enhance effectiveness rather than detract from it.

• Size and Thickness

In general, larger is often better when it comes to chromium carbide plates. A larger, thicker plate enhances durability and effectiveness in protecting your equipment.

• Primary Goal: Protecting Equipment

These considerations are essential; avoid randomly purchasing a chromium carbide plate as it may cause harm to your workpiece instead of offering protection.

How Can You Order Chromium Carbide Overlay Plates?

Ordering chromium carbide plates follows the same process as ordering regular AR steels. If you have a supplier in mind, reach out via their hotline, or alternatively, send them an email. It's advisable to indicate the required quantity in advance.

CHROME CARBIDE OVERLAY PLATE

CHROME CARBIDE OVERLAY PLATE

(IT'S NOT ALL THE SAME)

By

Bob Miller

Bob Miller is a metallurgist and wear consultant with Clad Technologies, Birmingham, Alabama 205-978- 

Introduction

Thirty years ago, Chrome Carbide Overlay Plate was produced by a limited number of companies. Due to its popularity and versatility for extreme abrasion applications, the manufacturer field has expanded. With advancing technologies, variations in production methods can significantly impact the end product's quality. This article aims to clarify misconceptions by detailing various manufacturing methods for overlay plates and their implications for quality, consistency, and wear characteristics.

The Basic Product

A Chrome Carbide Overlay Plate comprises a mild steel base plate overlaid with a resistant welded coating applied through an open arc or submerged arc method. Plate thickness typically ranges from 3/8" to 1-1/2"; widths from 4" to 8"; and lengths from 8" to 20". The overlay is usually composed of either one or two layers of 1/4" or 3/8" thickness, with bead widths generally measuring 1-1/2" and featuring random check cracking, a natural occurrence during welding, regulated by the overlay's chemical composition or cooling techniques. The overlay's chemistry typically ranges from 15% to 30% Chromium, 3.0% to 4.5% Carbon, with Manganese and Silicon varying from 1% to 4% each. Molybdenum may constitute up to 3%. Deposit hardness ranges from 400 BHN to 600 BHN, often centering around 550-600 BHN. These completed plates can be formed and machined, with holes cut using plasma or electro discharge machining (EDM) techniques.

Hardness, Chemistry & Wear

Historically, hardness has served as a misleading indicator of wear resilience. For instance, comparing an alloy steel with a white iron, both portraying hardness values around 550 BHN, reveals that white iron exhibits significantly superior wear resistance. This phenomenon can be attributed to the differing microstructures contributing to macro hardness.

Material

Hardness (BHN)

C

Cr

Mo

G65 (Wt. Loss)

Alloy Steel

550

0.50

3.50

0.50

1.40

White Iron

550

4.50

20.0

2.0

0.22

Mild Steel

90

0.25

0.00

0.00

2.51

C=Carbon, Cr=Chromium, Mo=Molybdenum

Disparities in wear resistance arise from the nature of the hardness tests. Common hardness testing methods like Brinnel and Rockwell assess macro hardness, while each metallurgical component possesses distinct microhardness values influencing the overall macrohardness. Therefore, understanding the composition and resulting microstructure becomes critical in evaluating wear resistance, as evident through wear tests like ASTM G 65.

Wear Testing ' ASTM G65

Various forms of wear exist, with scratching abrasion being highly prevalent in the mining sector. A method for quantitatively assessing material resistance to scratching is the Dry Sand Rubber Wheel Test, or ASTM G65, which evaluates materials based on weight loss under controlled laboratory conditions. While field conditions can be influenced by additional wear factors like impact and corrosion, examining test results alongside a material's chemistry and microstructure reveals essential insights regarding potential field performance.

Methods of Manufacture

Since the initiation of Chrome Carbide overlay plate development, numerous manufacturing methods have emerged. Current popular approaches can be categorized as follows:

1. Arc Welding Process Employed
   1. Open Arc
   2. Submerged Arc or Fusion Bond Welding
2. Base Plate Configuration
   1. Flat Plate or Table Design
   2. Cylindrical Drum

Selecting among these variables can significantly impact the overlay plate's quality, consistency, integrity, and wear characteristics. Detailed evaluations of each variable are provided below.

Arc Welding Process

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Two primary welding techniques utilized in cladded plate production involve open arc welding and submerged arc welding. Each method has unique characteristics and limitations. It's crucial for consumers to recognize the welding technique employed, as it directly correlates with wear resistance, as elaborated below. Firstly, some clarifications are required:

• All arc welding deposits encompass a blend of wire and base metal compositions, expressed in dilution percentages. For instance, a 30% dilution factor indicates that the weld comprises 30% base material and 70% wire.
• The deposits mentioned are uniformly mixed, lacking visual separation between the base and wire components—resulting in a homogeneous alloy.

Open Arc Welding:

Open arc welding utilizes a core wire with no added gas or flux. All necessary components, including slag, flux, gas covering, and alloys, are embedded within the core. The wire consists of low carbon material, with essential ingredients added during the manufacturing process. The wire is packaged for distribution in 500 lb containers. As the sole welding consumable for plate fabrication, inventory management is relatively straightforward. Process control is simple, focusing solely on controlling arc voltage, current, and wire feed rates. Although deposits yield smooth results, they may exhibit roughness and inadequate bonding between weld beads. The primary limitation of the open arc technique is its reduced capacity to achieve chemical compositions that maximize wear resistance in the initial layer. Due to constraints from wire production and process variations, the typical output is roughly 30% Chromium and 5% Carbon. Additionally, open arc welding often results in approximately 40% dilution, leading to a deposit composition of around 18% Chromium and 3.0% Carbon. ASTM G65 abrasion tests reveal that a minimum of 20% Chromium and 4% Carbon is necessary for reliable wear resistance, indicating that while the second layer also experiences dilution, it tends to yield acceptable performance under specified conditions.

Submerged Arc / Fusion Bond Welding:

In submerged arc welding, a solid or cored wire is employed alongside added flux. The arc melts both elements to form a weld bead and generates a removable slag covering. Typical dilution rates range between 30% and 40%. Fusion Bond Welding, also a submerged arc technique, utilizes added alloy powder, reducing dilution to about 10%. This method enables the addition of alloying elements to exceed the dilution factor, allowing deposition of chemical compositions like 30% Chromium and over 4.0% Carbon in the initial layer, which aligns well with wear requirements.

Furthermore, features inherent to the Fusion Bond Welding process result in smooth deposits with shallow peaks and valleys, enhanced process control, and consistent deposition characteristics. Nevertheless, this method requires maintaining inventories for three different welding consumables—wire, flux, and alloy powder. Nonetheless, this flexible approach in adjusting welding processes and chemical compositions generally outweighs these logistical challenges.

Condition

Dilution (%)

C

Cr

G65

(Wt. Loss)

Open Arc Wire

5.00

30.0

Open Arc 1st Layer

40%

3.00

18.0

1.25

Open Arc 2nd Layer

40%

4.20

25.2

0.40

Sub Arc 1st Layer

10%

4.30

28.0

0.33

Sub Arc 2nd Layer

10%

4.55

30.0

0.19

Mild Steel

2.51

Base Plate Configuration

A36 or flat steel plates of varying sizes are employed in overlay processes. Manufacturers have two options: (1) retain the flat shape while positioning it on a specialized flat table for overlays, or (2) roll the flat plate into a cylindrical form, weld the seam, and set it on a horizontal turning device for the overlaying method. Each approach presents distinct advantages and disadvantages, with their respective choices affecting the final product's overall quality and integrity.

Table Method:

The primary benefit of this configuration lies in its ease of handling. The flat plate can be simply placed on a table for overlay. Post-overlay, the plate undergoes straightening and is trimmed to dimensions via plasma cutting. Although this method is straightforward, complications can arise during the welding of plates less than 3/4" thick. Distortions in the form of large bumps can compromise integrity, with increased penetration and dilution during the welding process potentially making the affected area's chemistry unacceptable for maximum wear performance.

Drum Method:

The primary drawback of this approach is the excessive manipulation required. Initial rolling into a cylinder and seam welding must occur before placing it on the turntable for overlay. Following the overlay, the resulting drum needs to be plasma cut and flattened before final trimming. Despite these challenges, the drum method ensures distortion is minimized, allowing process control to optimize. Consistent chemical composition and reliable wear properties persist throughout the plate.

Conclusion

Identifying various manufacturing methods for overlay plates underscores each method's unique appearances and limitations. As technological advancements continue, additional processing methods will be introduced, evaluated, and potentially refined based on consumer acceptance. The current options will also experience iterative improvements where justified. For overlay plate consumers, equipping themselves with the knowledge detailed here can aid in discerning quality among suppliers. A simple checklist might serve as a useful guide when evaluating overlay plate vendors.

1. 1. 1. Welding Method
         • Sub Arc Bulk Welding
         • Open Arc
         • Other
      2. Plate Configuration
         • Flat Table
         • Cylindrical Drum
      3. In-House Wear Testing
         • ASTM G65
         • Outside Source
         • Other
      4. Quality Control Method
         • Wire Chemistry
         • Deposit Chemistry
         • Hardness
         • Wear Test
         • None
      5. Frequency of Testing
         • Each Plate
         • Periodically
         • Upon Request
         • Not Available
      6. Certification
         • Specifications
         • Actual Test Results
      7. Sizes
         • Thickness, Lengths, Widths
         • Cladding Thickness
      8. Availability
         • Days
         • Weeks
         • Months

Reprinted Articles courtesy of cladtechnologies.com

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