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WALDUN overlay plates have served friends from Global Coal-fired Power, Cement, Mining, Iron & Steel and etc.
Why WALDUN Overlay Plate is Different
R&D Team:Strong R&D team on overlay plate hardfacing technology.
Customized Overlay Plate Products: We also supply customized overlay plate products in line with our customers’ demand.
Delivery: On-time delivery accompanied by a flexible payment plan.
Trade Terms: Our company welcomes Fob, EXWORK, CIF, and other trade terms.
Packing: The packing is strictly in line with the customs requirements.
Since you have equipment with components that slide against each other, exposed to abrasive and corrosive materials or have impact damage. You are right here to make your equipment more stronger to fight with tear and wver.
WALDUN can always provide over plates solution with good service. Meanwhile, you can get competitive rates for overlay plates and abrasion resistant steel parts. such as steel mills, pipe mills, aluminum mills, chemical companies, mining, military, etc.
Chromium carbide overlay plates or steel liners are used in many applications where friction between two parts or materials creates degradation. Overlay plate steel plate may bolt onto a machine that slides in and out or up and down in a manufacturing process, while they can also be found where manufactured parts or minerals are regularly rubbing or abrasively contacting the machined plate.
Tungsten carbide overlay plate is composed of Q235 or Q345 steel plate and wear-resistant layer. The base of the wear-resistant layer is metallurgic bonding, which fixed with low hydrogen sodium type flux-coated welding wire and other individual welding electrodes. One or more layers can compound it.
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.
1. 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.
2. 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.
3. 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
4. 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.
5. 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.
6. 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
7. 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㎜;
8. 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;
9. 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.
10. 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.
11. 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.
12. 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!
Weld Overlay Plate – The Ultimate FAQ Guide
Protecting your machineries and equipment must be your priority. Aside from the fact that they’re expensive, it can be a lot of hassle for you, too!
One of the best ways of making them more resistant to wear is through overlay plates.
What this guide will be, is a complete and a comprehensive guide about overlay plates. We’ll discuss what overlay plates are, how they can help you, and where they’re best used.
What is an Overlay Plate?
Overlay plate is a type of material that you use to lengthen the lifespan of your equipment.
Its main purpose is to make a part or a component more resistant to wear, abrasion, corrosion, etc.
What is a Weld Overlay?
A weld overlay is a process of depositing or welding metals to particular surfaces or parts.
The main goal is to improve and enhance the characteristics and properties of the base metal.
How is an Overlay Plate Made?
Overlay plates are made via the process of multi-pass open arc welding.
More often than not, Chromium Carbide Alloy is the material deposited to the steel, making it a clad plate.
What is the Weld Overlay Process?
You can easily distinguish a weld overlay process because it will involve different metals.
The process is simple – two or more metals are used and combined together, being welded to the base metal layer’s surface.
The Best Material For a Weld Overlay Plate
Chromium carbide alloys are arguably the best material for a weld overlay plate.
Using them can help and allow you to strengthen and enhance your base metal’s properties. Without question, it will develop its ability to be more resistant to wear and other damages.
What are the Different Weld Overlay Plate Processes?
Weld overlay can be done through a myriad of different techniques.
However, the most common ones include:
Submerged Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW) (Gas-Shielded and Open Arc Welding)
Shielded Metal Arc Welding (SMAW)
Plasma Transferred Arc Welding (PTAW)
These are among the most effective for the welding overlay process.
What is the Usual Hardness of an Overlay Plate?
Different overlay plates have varying hardness. Some are hard but brittle; while some are soft but flexible enough not to be broken.
However, a Chromium Carbide Overlay (CCO) plate has a hardness of about 700 to 850 BHN.
What is a Chromium Carbide Overlay Plate?
CCO for short, it is a plate that is considered as one of the hardest in the market.
It contains many different additives that provide higher and better resistance to:
What is a Smooth Overlay Plate?
While regular overlay plates are distinctive with their wide and smooth beads, they’re quite different.
Smooth overlay plates are regular clads that have a smoother exterior than what is expected of the product.
Nevertheless, they still contain the same properties and characteristics. The difference is only with the exterior.
What are the Benefits of Smooth Overlay Plates?
Using smooth overlay plates can actually give you more benefits than you can imagine.
In fact, here are the top pros that you can have for smooth overlay or CCO plates:
Little-to-no weld beads in the final product
No friction because of the smoothness of the surface
Can last longer and more effectively than regular wear plates
More cost-efficient and can be a one-time solution for high-friction activities
Which Industries Can Benefit From Using Overlay Plates?
Many industries can find benefit from utilizing overlay plates.
However, some industries that can find the most use for it include:
Manufacturing and Milling Industry
Gas & Oil Industry
Is Wear Plate and Overlay Plate the Same?
Ideally, they are the same type of product with the same goal. They’re both used for protection and for development of the base or the parent metal.
You can think of it like this:
Wear plates are the general type of protection for parts and components.
Overlay plates, on the other hand, are extra hard plates with better resistance properties.
Clad Plate vs. Overlay Plate
Although they have different uses and goals, their overall effectiveness is compared frequently.
Clad plates are used to improve a material’s resistance to abrasion, corrosion, etc. It’s usually done when a product is new or if it’s just been slightly used.
Clad materials are best used in machinery and equipment to perform better; to have less damage.
Overlay plates, on the other hand, have different purposes. They can be to restore the shape and dimensions of a part or a component, to prevent further wear, and so on.
Overlay plates are used for purposes to lengthen its life by deterring wear and damage; as well as to protect the surface from being cracked, scratched, and be consumed by abrasion.
What is Stomata in Welding?
Stomata is one of the many welding defects.
You can accidentally form Stomata when bubbles can’t escape during the solidification process.
It’s the result of having insufficient flux coverage, or by having a large slag viscosity.
How Can an Overlay Plate Help You?
Overlay plates can help you with a lot of things, such as:
Less broken parts or equipment
Superior strength and durability
Whatever industry you may be in, you’ll find that overlay plates can absolutely help you!
Whether you’re looking to restore shapes or dimensions of a machine or equipment; or if you’re trying to prevent further damage to the part or component, it’s the best choice to make!
Who Can You Trust With Overlay Plates?
There are a lot of companies you can work with if you need overlay plates.
Whether you need to purchase overlay plates, or you’re looking for a partner – we here at Waldun are always ready to give the assistance you need.
We can help you with premium and high-quality Chromium Carbide Overlay plates. Our plates are made and designed specifically for areas that have high abrasion under moderate temperatures and impact levels.
What is the hardness of the overlay plate?
Overlay plate welding layer has an extreme hardness.
The micro-hardness of carbide can reach above HV1700-2000, and the surface hardness can reach HRC58-62.
What is the flatness of the overlay plate?
Overlay plate flatness shall be controlled within ±3mm/m.
Our advanced welding process strictly controls the deformation of the welding.
Also, after welding, we use a leveling machine to level the overlay plate.
How to manufacture a overlay plate?
We have 7 major steps to manufacturer a overlay plate. Our advantages is to welding a big plate by CNC system at one time.
Step 1 Rough cutting: cutting the raw material into a rough size plate, like 1500X3000mm.
Step 2 Welding: open arc welding or submerged arc welding overlay on the substrate. Usually, one square meter of a overlay plate takes 4 hours, for example of 6+4.
Step 3 Inspection: this is to check the overlay plate’s quality if there is a welding defect on your plate.
Step 4 Repair welding: this is the repair of welding defects.
Step 5 Precision cut: cut it to the size you need.
Step 6 Leveling: using a leveling machine to level your overlay plate to your desired levelness. Normal is at ±3mm/m.
Step 7 Punching and stud welding: this can be done according to your specific requirements. If you have other requirements, you can contact us.
How to control the quality of overlay plate?
When plan to purchase overlay plate, you shall mostly focus on the quality. The best quality control better adopts process quality management. That’s what we are doing.
Waldun has always been dedicated to provide good quality products. We test the overlay plates strictly.
To prusue good quality and customer satisfaction, we have certified with ISO9001 quality management system, ISO14001 environmental management system. We sincerely provide high quality wear resistant solution products and services to customers.
We will always supply our best products, adhere to quality first and keep up the spirit of striving for perfection.
How long is the delivery time of overlay plate?
Generally it is 5-10 days if the goods are in stock. or it is 15-25 days if the goods are not in stock, it is according to quantity.
Can i get free sample of overlay plate?
Yes, you can get the sample free of charge.
What is payment terms of overlay plate?
We accept TT,LC.If you have good credit, we can accept OA.
Can i get after service if i buy overlay plate?
WALDUN has a professional after-sales service team and we are able to quickly solve customer’s problems. If there are any quality problems, the responsible person will provide reasonable solutions within 12 hours after being notified.
Ordering a overlay plate from WALDUN
In some cases, we can modify your equipment to incorporate these overlay plates when not in the original equipment design. If your equipment has lost some efficiency or does not hold the same tolerances as new, inspect the worn parts. There could be an easy and cost effective fix to the problem.