Chromium Carbide Overlay (CCO) Wear Plate

Buying Guide for Chromium Carbide Overlay (CCO) Wear Plate

Chromium carbide overlay plate is one, if not the most popular and the most sought after wear plate in the industry. Because of their wide availability, their efficiency, and their effectiveness, it’s easy to see why they’re the best. And while you may think it’s easy to choose from countless chromium carbide overlay plate suppliers, it’s actually the hardest and the most challenging part. A chromium carbide overlay (CCO) overlay plate manufactured and processed by WALDUN Today, we’ll be giving you a guide on how to purchase chromium carbide overlay plates. In fact, by the end of this guide, you’ll know everything you need to look for before deciding which manufacturer to work with! Not only that, you will also know how you can buy the best and the highest quality of CCO wear plates without ever spending a fortune! 1

Understanding Chromium Carbide Overlay Wear Plates

In discussing chromium carbide overlay wear plates, it isn’t just limited to one kind.

This is a sample of WALDUN’s regular CCO wear plates – we also have smooth CCO plates, etc. As a matter of fact, you can find many different kinds and variations of CCO wear plates in terms of pattern, type, procedure made, and the like. In this buying guide, we will help you find the best CCO wear plates in the market. We’ll dissect everything from the chromium carbide wear plate manufacturer, the type of material used – to the finishing procedure.

How Chromium Carbide Overlay Wear Plates are Made

In the simplest and the easiest terms, here’s a quick peek of how chromium carbide wear plates are manufactured: Plasma cutting is done to produce the required shape/dimensions of the wear plate

1. The steel plates are sourced out and are run through rotating tubes. They’re bended for them to drum.
2. If the client requires a large-sized CCO wear plate, then smaller steel plates would be welded together to make up a large part.
3. Then, using welding, the plate is cladded by the material – in this case, chromium carbide at the surface.
4. Depending on the size of the steel plate would be the number of the welding heads running simultaneously.
5. After cladding, plasma cutting and other cutting procedures are done to produce required shapes and dimensions of the CCO wear plates.
6. Then, depending on the manufacturer, the final product is heat treated to a temperature it can resist. This treatment is done to harden the wear plate further.

That’s the general procedure on how a CCO wear plate is produced and manufactured. Other manufacturers might have other methods and processes; that’ll depend on the manufacturer already.

Purpose of Chromium Carbide Overlay Plates

Chromium carbide overlay wear plates are used by a lot of industries because of the promising results they’re guaranteeing. An example of what would happen if there’s no wear plate installed or integrated As a matter of fact, chromium carbide overlay plates are perfect for situations and environments that have high abrasion, high corrosion, and high friction. You can use CCO plates for:

• Prolonging the life or the effectiveness of machines and equipment
• Restoring or rehabilitating the dimensions and the shape of parts and components
• Decreasing and overall removing the risk of the parts wearing out
• Controlling the abrasion-level of each of the machine or the equipment’s part or component
• Helping the overall effectiveness and efficiency of the part/component

Those are the main and primary purposes of chromium carbide overlay wear plates. All of these are applicable to many different industries and sectors; it’ll just depend which one you are in.

Having More Layers – Are They Better?

When dealing with CCO wear plates, the wide majority of people think that the more layers a particular wear plate has, the better. A multi-layered chromium carbide wear plate for strength and durability purposes Since their main purpose is to absorb friction and abrasion, not letting it reach the part itself, you’d think the same, right? However, that is not true. Having more does not always translate to good or better. Even if there’s just one pass or one layer of chromium carbide wear plate, if it has been welded properly and appropriately, and if the chemistry of the elements and compounds are compatible with one another, it’ll be better than a normal and a regular CCO wear plate that has a double pass.

Industries That Use Chromium Carbide Overlay Plates

Many industries and business areas feel the need to use chromium carbide overlay wear plates. The Pulp and Paper industry – one of the industries that use CCO wear plates The most common industries that are vocal about their need to use CCO wear plates include the construction or the structural industry, and the heavy earth moving industry. To cite other industries that need it, they are:

Gas and Oil Industry

The gas & oil industry use wear plates for many different parts and components, including valves, boilers, heat exchangers, compressors, chutes, conveyors, and many more.

Pulp and Paper Industry

For the pulp and paper industry, wear plates are regularly applied and integrated to refiners, pulpers, chippers, cyclone fans, mixing machines, pipelines, etc.

Mining or Coal Mining Industry

With the mining and/or coal mining industry exposed to frequent abrasion and friction, the use of wear plates has been seen as a standard in many different situations. As a matter of fact, the most common machines/equipment that are installed CCO wear plates on include dumpers, bulldozers, graders, excavators, rotary blades, loaders, and many more! Apart from those industries, there are other industries that rely on chromium carbide overlay wear plates for the life and the prolonging of their parts/machines.

Does Paint on Wear Plate Really Matter?

The quick and easy answer to that is no – wear plates, especially chromium carbide overlay plates wouldn’t have too much of a difference if it has solid paint or not – or if the paint is cranked and mixed up. This probably is the most common misconception that experienced and seasoned workers have when choosing CCO wear plates. Color shall never be a side of judgment in choosing which CCO plates to buy. As a matter of fact, you might even see hairline cracks, check-cracks, and other thin lines on the CCO plate when you first purchase it. To be fair, they’re completely normal! Seeing a thin-line crack isn’t a sign that the CCO plate has been damaged or worn-out; it is, in fact, a natural stress relieving effect that the plates have.

How to Choose the Chromium Carbide Overlay (CCO) Wear Plate to Buy

There are a couple of things you should look for before you purchase chromium carbide overlay wear plate. WALDUN’s chromium carbide wear plates stacked and lined with one another As mentioned above, the thickness or the number of passes isn’t significant enough if the chemistry is not thought of fully. That being said, here are the best tips so you’ll be able to purchase the best and the highest quality of CCO wear plates.

Bigger Plates are Always Better

While pass thickness isn’t much of a big deal, the larger the size of the CCO plate, the better. Imagine a wear plate that’s smaller than the bucket you’re trying to cover. Also, if you are going to install it on a loader or an excavator, would a small one fit it? Probably not! There are manufacturers that produce large-sizes chromium carbide overlay wear plates, while those that just weld two (2) or more small pieces together. You need to make sure that you’re purchasing large and wide-sized CCO wear plates for better results. So, checking on the history, the background, and the overall capability of the manufacturer is important. We’ll get to that in a later part of this guide.

Ask For Samples

Most, if not all CCO wear plate manufacturers offer free samples to clients and businesses. These samples are ways to check if the product or the CCO wear plate is fit to the need of the client. Should they provide a sample, you can do and perform tests and assessments to that particular sample. But, there are a few chromium carbide wear plate suppliers that do not offer samples; it’ll be better to work with a manufacturer that provides free samples.

The Hardness Level Isn’t Always Important

Different chromium carbide overlay wear plates have different hardness levels. The hardness would depend on a wide range of factors, such as the heat treatment, the material used, and many more. On average, the hardness levels of chromium carbide overlay or CCO wear plates are usually around 59 to 64 HRC. But, the harder the wear plate is, the more brittle and fragile they are. High-level hardness CCO wear plates are prone to cracking, breaking, and splitting.

How is Hardness Measured?

To add extra information and knowledge to this, here’s how hardness is measured. Measuring the hardness of a particular item can be done in many different ways. However, the most common ones are the Brinell and the Rockwell scale. Typically, measuring the hardness of CCO wear plates is done via the Rockwell (HRC) or the Hardness Rockwell C. 59 HRC, when converted to Brinell, is 590 HB. 64 HRC, on the other hand, is measured ad 668 HB. The higher the number, the harder the particular item or CCO wear plate is. So, it might seem typical to see the regular or the average hardness level of chromium carbide overlay wear plate is at 59 to 64 HRC. However, different manufacturers, use different materials and products to produce and to manufacture CCO wear plates – they’re not all the same. There are manufacturers that produce malleable CCO wear plates, while there are those that manufacture CCO wear plates that have HRC levels over 72.

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.

Stomata

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.

Undercut

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

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.

Other Factors You Need to Consider

In choosing the CCO wear plate, you don’t just have to focus on the hardness. There are other properties you can choose from as well. Apart from hardness, you also need to consider other factors and properties

Service Temperature

This property measures the capacity of the CCO wear plate to be worked on under temperatures. If we put it in average, the maximum service temperature of these plates is at 600 to 650 degrees Celsius or 1,100 to 1,200.

Impact

When it comes to the impact, this is the capability of a CCO wear plate to be able to resist and absorb impact.

Abrasion

The amount of abrasion resistance of a particular chromium carbide overlay plate depends on the composition of it. Abrasion refers to the wearing out of the surface such as scratching, rubbing, and marring.

Service Life/Life Expectancy

Lastly, the service life or the lifespan of the CCO wear plate is relevant and significant as well. Although the life expectancy would still depend on usage, as well as other external influences, manufacturers give the expected service life of their CCO wear plates for clients to have a general threshold of until when they’re effective.

Look Into the Manufacturer/Supplier’s Capability

While these things are a lot to digest, the best thing to do is to still look into the legitimacy and the experience of the manufacturer you’ll be working with. The quality and the overall effectiveness of chromium carbide wear plates will, of course, depend on the one who made it. If the chromium carbide wear plate manufacturer isn’t reputable or if they’re known to provide CCO wear plates that are not-up-to-standard, then you should already think twice about working with them.   To illustrate further, there are newer manufacturers of wear plates that skip heat treatment because they think it’s not a collaborative factor in the strength and quality of the material. These manufacturers are obviously inexperienced and are not used to other procedures in which wear plates are used for. To successfully check the background or the history of a manufacturer, you can try the following:

Check Reviews

While the reviews you see online aren’t much impacting, the reviews that real clients they had could be everything you need to decide. If you see a line of reviews that is 100% positive – then, the chances of that manufacturer being world-class is higher, you can immediately come up with a conclusion that they’re easy-to-work-with.

Speak to Previous Clients

Another thing you can do is to find previous clients of that particular manufacturer. Try communicating with those clients and ask about the service and the products the manufacturer is offering. Were they up to the expectations of the client? Or were there a lot of challenges towards completion?

Check Their Manufacturing Plant/Office

Lastly, the condition or the ambience of the manufacturing plant reflects directly on the quality of service the manufacturer has. The plant or workspace reflects the quality of products and services Since the rise of technology, many suppliers opened a virtual setting of their manufacturing plants and offices. This paved way for clients to be able to “visit” their factories without being physically there. Oftentimes, the best manufacturers would offer a virtual tour of their factory. They wouldn’t be shy to let their factories and their manufacturing processes out.

Which Manufacturer Should You Trust?

It has been a long debate in terms of which manufacturer you should work with. Some businesses and companies say that choosing a Western manufacturer is better (those in Europe and in North America), while some say that you’ll be able to get the best products in China. The latter, probably, is the closest because of a lot of different factors:

• Cheap, inexpensive, and affordable goods
• High quality of products (ODM and OEM)
• Many variants and variations of the orders and the products you need
• A lot of manufacturers to choose from (tight competition, better quality)
• And many more

But out the hundreds of chromium carbide wear plate manufacturers in China, which one should you trust and work with? For more than a decade, we here at WALDUN have been crowned as the best, the most trusted, and the most reliable CCO wear plate manufacturer. The quality and the overall finesse that we have in CCO wear plate manufacturing has been key to our journey atop the industry’s ladder. WALDUN’s processes have been deemed and considered as the most significant – because it’s foolproof and other manufacturers have imitated it.

Business Advantages of Working With WALDUN  

Apart from the experience, the skill, and the overall adeptness that our engineers and experts have, we’re also a company prepared to give you everything you need and everything you want to know about. If you yearn to learn more about chromium carbide wear plates, we got you. If you’re interested in innovating with us, our Research & Development (R&D) Team is prepared to help! Being ISO, ASTM, and SGS certified – you can trust us with everything from product sourcing, customization, down to logistics and shipping! Get the best and the highest quality of chromium carbide wear plates from WALDUN at the most affordable and the most competitive prices!

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