Many companies in the fabrication industry aren’t aware of what CCO plate is.
Little did they know that this piece of material would be everything they need for the improvement of their parts. In case you’re also not sure what it is, don’t worry, this guide is perfect for you.
This will be the best, the most detailed and the most comprehensive guide about CCO plate! We’ll thoroughly discuss what CCO plates are, how you can use them; literally everything about it!
What is a CCO Plate?
Short for Chromium Carbide Overlay plate, CCO plates are made for wear and abrasion.
We can define a CCO plate as a hard clad plate that contains properties and substances that have high resistance to abrasion, temperature, and stress.
You might not know it, but it’s actually used by many different businesses.
What Uses Can CCO Plate Have For You or Your Business?
The main use of a CCO plate is to provide long-lasting support to parts and components. Since it’s extra hard and highly resistant to wear, you can use it to:
Improve the life of your machines and equipment
Prevent further wear of a certain part or component
Add strength and resistance to your materials
Ideally, you’ll use CCO plates because of the strength properties and resistance they have.
Which Industries Use CCO Wear Plates?
Think of all the industries that undergo stress, impact, and friction; all of those would need CCO wear resistant plates.
To give you a more concrete answer, here are the most common industries that use CCO plate:
Iron and Steel Industries
Coal Processing and Mining Industries
Cement and Construction Industries
Power & Generation Industries
And Many More!
These are all industries that usually engage in activities that have high impacts and temperatures. But, the use of CCO plates aren’t just limited to these!
How Hard are CCO Plates?
The hardness of CCO plates usually depends on the manufacturer; as well as the procedure on how it’s done.
However, the average hardness that it has is around 700 and 850 in the Brinell Hardness Scale. Alternatively, it’s between 58 and 62 HRC.
How Are CCO Plates Made and Manufactured?
A CCO plate is manufactured and created through the deposition of materials on mild steel.
The materials that would be deposited are abrasion resistant, rich in chromium type of components.
Through this process, a CCO plate is created and manufactured. After it, certain processes follow allowing it to be qualified for application to a parent metal or a workpiece.
Are CCO Plates Wear and Abrasion Resistant?
Yes, CCO plates are wear and abrasion resistant.
This actually is their main purpose – to provide the resistance that a certain part or component needs.
What Advantages Can CCO plate Give You?
The application of CCO plate on your parts and/or materials can give you a ton of benefits. Some of which include:
Higher Resistance to Wear and Abrasion
CCO plate improve and develop a part or a material’s resistance to abrasion and wear. Their composition is perfect for the strength and durability of materials.
Moderate to High Level of Impact Resistance
Because of its metallic properties, it’s also perfect for moderate to high levels of resistance. It can absorb shock in high different levels.
Imagine any construction material without a CCO plate coated to it; you’d have to purchase new parts or equipment.
With CCO plate, you can protect its surface, heightening the overall durability, longevity, and strength that it has.
CCO plates are all made and used for the benefit and the strength of your machines or equipment. You can count on it to prolong the lives and improves its resistance to wear.
What is a Manganese Plate?
It’s a wear plate made from materials that are non-magnetic and austenitic.
It just sits below the hardness level of CCO plate at about 450 to 500 BHN.
Chromium Carbide Overlay Plate Price
Prices of CCO plate would depend on the manufacturer. In fact, more often than not, manufacturers don’t just display the prices online.
But, to give you an idea of how much it is on average, a ton of CCO plate costs somewhere about $900 to $1,500.
What Should You Consider Before Buying a CCO Plate?
Many experts suggest considering a couple of things before purchasing a CCO plate. These recommendations include:
Chemistry of the CCO Plate
There are CCO plate that contain various chemistries for their chromium carbide plates. These chemistries could contribute and complement whatever your workpiece is.
Look for chemistries that would improve your parts or components, not destroy it.
Size and Thickness
Bigger is always better – especially in the case of CCO plate. The bigger, harder, and thicker a plate is, the better.
Its main purpose is to protect your equipment, right?
These are just two of the things you need to consider. Refrain from just purchasing random CCO plate because it can break your workpiece instead of improving and developing it.
Where Can You Find the Best CCO Plates?
There are a ton of manufacturers and suppliers of CCO plate in the industry. But we here at Waldun are considered as the best and the most reliable.
We’ve been specializing in wear plate since 2005, and we’re on a constant improvement to provide high quality CCO plate to our clientele.
Why Trust Us For Your CCO plate?
All our CCO plates have been crafted and formulated with passion, learning from each client we encounter. The equipment we utilize are state-of-the-art, and are also manufactured by us.
You can trust us for the supplication of CCO plate for we’ve worked with hundreds of businesses in the past decades. Moreover, you can expect your plate to be delivered to you within 20 days from the date of your order.
Plus, we can give you a free sample to see if it’s what you’re looking for! You will never fail when you choose us for your CCO plate needs here at Waldun!
Overlay Plate – The Ultimate Buying Guide
You’ll get the most out of this guide if you need to learn overlay plate (AKA wear plate) is exceeded only by your willingness to execute and make a purchase.
How do you determine where to purchase overlay plate from? How do you tell which overlay plate provides you the best wear life to get your equipment back up, quickly? Here are a few factors you need to consider when purchasing or researching overlay plate.
Combine this information with some practice and you are well on your way to becoming a savvy CCO plate expert.
The overlay plate has surfacing layers. How about flatness?
Based on industrial standard, the flatness of the overlying plate shall be control within ±3mm/m. so you may ask how to make sure of the wear plate flatness.
Then how to test the exact flatness of chromium carbide plate?First of all, the steel plate should place on the flat ground. It is simple to use a steel ruler with the ruler standing on the steel plate. Measure the maximum distance between the lower end of the ruler and the steel plate, corresponding to the shape of the steel plate.Second, there are special tools for higher accuracy. Measuring straightness by using a very rigid rectangular section ruler with a measuring scale similar to a depth gauge.Third, a laser shaper for automatic measurement is a more advanced test method.
All three principles are the same, but that the speed and accuracy are different. You can check overlay plates by your tools at hand.
Can CCO plates have welding cracks?
Answer is yes. overlay plates, welding cracks shall be evenly spaced, and the cracks shall be fine.
The production process of a wear-resistant composite plate is made by metallurgical surfacing, either open arc welding or submerged arc welding. Welding current is generally 500 ~ 700A, and the temperature of the welding arc reaches 6000 ~ 7000 ℃.
The instantaneous high heat causes the welding wire and the base plate to reach the melting point to form a molten pool (so-called bead), and the alloy powder added to the molten pool is melted to form a surfacing layer.
In the cooling process after thermal deformation, to release the welding stress existing in the surfacing composite steel plate, many cracks of different sizes will be generated in the direction of the surfacing layer perpendicular to the bead.
This crack is the result of stress release. Therefore, if there are no cracks or few cracks on the surface of the overlay plate, it is an unqualified product! These cracks seem to be very easy to worry about. They are afraid that the wear-resistant composite steel plate will spread into the base plate during use, and even they are scared of breaking or falling off. This worry about cracks is unnecessary.
Production belongs to metallurgical combination and has excellent bonding performance. The blow does not fall off or break during use. As long as the crack intervals are uniform and the cracks are small, there is no problem.
How to test and make sure of the surfacing layer size?
It is best to use UT for testing. UT thickness measurement is possible. The echo from the interface between the two materials is visible due to the slight velocity difference between carbon steel and stainless steel cladding. However, repetition is minimal. Do not use a thickness gauge with a digital display. UT instrument with A-Scan presentation is necessary.
If UT is not available, can measure after grinding, the surfacing layer shall be visible, flat and no unevenness, and the average thickness is measured at multiple points
How to judge an overlay plate with surface painting?
We all know the saying, “don’t judge a book by its paint.” Ironically the same goes for CCO plate. One area of concern is the cracks that appear. The surface of the plate will exhibit numerous hairline cracks, which are a natural stress-relieving phenomenon that is essential to the performance of the plate. It enabled the plate to be formed, bent, and rolled without damage. These operations are maybe necessary for your replacement parts.
Sometimes plates are entirely painted. It may make the plate appear aesthetically pleasing, but this is a tactic to cover imperfections or inconsistencies in the welds. Proceed with caution when dealing with companies that provide fully painted plates. The exception would be when the customer specifications require this step.
Can overlay plates have welding defects?
The quality defects of the wear overlay welding are common. When the relevant technical personnel inspects the welds of the chromium carbide overlay plate, they should find the defects early and limit the welding defects to a specific range to ensure the safety, economy, and stability of the unit. Run. The following is an analysis of these defects.
The most common occurrence of chromium carbide plates during welding is hydrogen pores, which are divided into internal pores, surface pores, and joint pores. The leading causes of pores are: the edge of the bevel is not clean, there are moisture, oil stains and rust, the electrode or flux has not been baked according to regulations, the core is destroyed, or the coating has deteriorated or peeled off. Due to the existence of pores, the useful cross-section of the weld is reduced. Excessive pores will reduce the strength of the weld and damage the compactness of the weld metal.
The depression left at the edge of the weld is called an undercut. The cause of undercut is due to excessive welding current, fast bar speed, too long arc, or improper angle of the electrode (wire). Undercuts reduce the working section of the base metal joint, which causes stress concentration at the undercuts, scattered in important structures or dynamic load structures. Undercuts are generally not allowed, or the depth of undercuts is limited.
Slag inclusion is the slag remaining in the weld. Slag inclusion also reduces the strength and compactness of the weld. The leading causes of slag inclusion are a. Residual slag left by aerobic cutting or carbon arc gouging at the edge of the weld; b. Bevel angle or welding current is too small or welding speed is too fast; c. “Dross” is formed because the flow is too low, or the rod is improperly moved. D. When alkaline electrodes are used, the slag will be caused by the arc is too long or the polarity is incorrect.
Not welded or fused
When welding the chromium carbide plates, the root of the joint is not completely melted. It is called non-penetration; there is local non-penetration in the weldment and weld metal or weld layer. It is called the unfused. Therefore, no essential structural parts are allowed to be incompletely welded or unfused.
How about overlay plate cutting edges?
Cutting edges shall be all around: linear, no burrs; it is best to use a large plasma cutter.
A precision cut surface has the following characteristics:
Square face (less than 3-degree bevel)
Smooth, with nearly vertical draglines
Little to no nitrides or oxides
Little to no dross, and what dross is present should be easy to remove
Minimal heat-affected zone and recast layer
How about the total thickness of the wear plate?
The answer for this question is the thickness shall be controlled within the allowable range, ± 0.5㎜;
How about the hardness of overlay plates?
Hardness shall be within the required range.
Due to the problem of the oxide layer and surface flatness on the surface of the wear-resistant steel plate, when testing the wear-resistant plate, it is best to mill off 1.0-2.5mm on the surface of the steel plate, and then perform hardness inspection on this surface. Generally, we recommend that you mill off 2.0mm for hardness inspection. The testing tool is preferably a desktop hardness tester (the data monitored by the portable hardness tester can only be used as a reference).
The general hardness is HRC55-62;
What is a suitable alloy composition?
If possible, measure and check alloy composition.
Not all applications are the same; it sounds like a simple thought. If requests are different, then shouldn’t the solution need to be changed? Consider looking for a company that offers multiple chemistries. If you have an extreme abrasion application, then you need a CCO plate that is tailored to meet the harsher abrasion and wear. For abrasion challenges that include impact elements, you need a solution that can handle the beating and not destroy the plate. Look for a company that can work with your needs, provides you a solution that addresses your specific application.
How about allowable metallographic?
If possible, do metallographic analysis. The volume fraction of Cr7C3 carbides in the metallurgical structure can reach more than 50%.
In the extension of chemistry, the most significant characteristic of the alloy overlay is its microstructure. Hence, when checked out under a microscope, the carbides will take the form of white substance against a dark background, that that’s the matrix.
A perfect microstructure, for more excellent abrasion resistance, must have a dense array of needle-like carbides that, in cross-segment, look as slender hexagons with a small hole in the middle.
Moreover, whenever you notice an appearance of uneven shaped spots or avenues of white. Such as either ladder, fish-bone patterns, or central poles with rungs on any of the sides. This is a sure sign that the carbon content is beneath optimum for high abrasion resistance, but it has also improved impact-resistant properties.
Which kind of supplier is trustworthy to buy wear plates?
The wear plate suppliers are different, and the products and production processes are different market position. The main is to look at the history of the supplier and the customer lists from suppler; the second, to see its scope of supply; the third, to see the boss, whether he is honest and reliable. Generally, the long-established manufacturer has a well-known reputation in the market and is always under the attention and supervision of people. The chromium carbide plates produced by him have reasonable quality assurance.
The test sample plate is a must before purchasing
Look at the material of its products. The selected wear plate must have a higher wear resistance. The wear plate must replace the machine to withstand severe wear during use. It must have excellent processing properties so that we can use it at any time, replace it with the wear-resistant parts we need.
It is best to check the sample. Through the test sample plate, we can conduct in-depth understanding and testing of the product, know how the product is processed, and know what characteristics the product has when it is used. Therefore, you need to look at the model before purchasing and using the wear plate to choose a product that you think is better and more suitable so that you can be assured when using it.
When it comes to purchasing the CCO plate, make sure to look deeper into the aspects of the plate and manufacturer providing it. Your down equipment needs to be repaired and stay operational for your site to make a profit. You do not want to throw your money away by compromising production time; you need to ensure the CCO plate you are proceeding with is the global standard in overlay plate.
Getting excited yet? If you get confused, don’t give up; we have folks who can help you with purchase of chromium carbide overlay plate. Contact us now!