WHAT IS WEAR PLATE?

Now, let’s explore each of them in details.

Wear Plates – The Ultimate FAQ Guide

Wear Plates are seen as one of the most important things that manufacturing and industrial companies need. If you own one, then you might have already considered using wear plates; but what are they actually for?

Many industries require using a wear plate for one or more machine parts they have. But in case you’re not sure what a wear plate is, we’ll help you!

This guide will be all about understanding what a wear resistant plate is. How it can help you, where you can apply it, where you can get it, and many more!

What is a Wear Plate?

A wear plate is an item that you use to keep your machines and equipment safe.

Wear Plate Image
Source: Welding Alloys

Commonly, you will use them to keep the parts of your machines and equipment safe from all kinds of damages.

Definition of Wear Plate

A wear resistant plate is an item that you can use to protect or secure machine parts.

Definition of Wear Plate
Source: Triton Alloys Inc.

You can apply and install it to a wide range of equipment, like crushers, buckets, chutes, etc. to secure and keep their performance.

Wear Plate Manufacturing Process

The procedure of manufacturing a wear plate is easy.

Wear Plate Manufacturing
Source: Pinterest

You can easily summarize it by following these steps:

  1. Raw Material Cutting
  2. Welding
  3. Inspection or Assessment
  4. Repair Welding
  5. Precise Cutting
  6. Leveling

You might find it different, but other manufacturers can have different procedures. This is just the raw or the general process on how it’s done.

The Importance of Using Wear Plates in Industrial Equipment

Industrial equipment are usually the machines that undergo the most wear.

Industrial Equipment

Horizontal color image of large group of automated injection moulding machines for plastic parts production.

Source: Twisty Industries

You use them 100% of the time, sometimes even 24 hours a day! Its importance in the industrial sector encompasses layering.

In fact, it’s also important because:

  • They can prolong the lifespan of a part or a component
  • Wear resistant plates can increase productivity and efficiency
  • Wear plates can enhance the quality of results

Uses for Wear Plates

You can choose to use wear resistant plates for many things.

Uses for Wear Plates
Source: Tech Acute

But, among the versatility of its uses, the most common reasons why it’s used are:

  • Prevent excessive and premature wear
  • Avoid damages like scratches, cracks, burrs, etc.
  • Increase or prolong the life expectancy of a part

Wear Plate HS Code

The Harmonized System (HS) code is a classification system used to identify goods and products.

All products traded have HS codes, it’s used for classifying good exportation and importation.

Wear Plate Material

Wear resistant plates are made out of different materials.

Wear Plate Material
Source: Kooben Technology USA, Inc.

You can have wear plates made out of abrasion resistant (AR) steel, aluminum steel, mild steel, etc.

Moreover, there also are wear plates made of hardened materials like:

  • A2
  • S7
  • 4140
  • And others

What are Bronze Wear Plates

It’s a type of wear plate you can purchase that uses bronze alloys instead of regular or hardened steel.

SAMSUNG CAMERA PICTURES
Source: National Bronze Mfg. Co.

You can choose bronze wear plates for their color and their physical properties.

Wear Plates Vs. Wear Pipes

How do wear resistant plates and wear resistant pipes differ? The answer is simple – their use.

Wear Pipes
Source: Sunny Steel

A wear plate is literally a “slab of thick material” that can be shaped, while a wear pipe is a cylindrical object that you can use for pipes, tubes, and other fittings.

Can Wear Plates be Used for Structural Parts?

Yes, you can use wear plates for structural parts. The most ideal hardness that can complement the industry would be about 350 to 500 HBW.

Structural Parts Wear Resistant Plates
Source: SSAB

Since the industry utilizes mild steel, it’s also worth noting that you can weld it with it too!

What are Hardox Wear Plates?

It’s a type of wear resistant plate manufactured by SSAB, a Swedish company.

Hardox Wear Plates
Source: Dinesh Tube India

Hardox wear plates are considered as one of the most popular types of wear plates in the industrial sector.

Hardox Wear Plate Characteristics

Because of its versatility and flexibility, you can use it for a wide range of applications.

Its most noteworthy characteristics include:

  • Superior and extreme hardness
  • Excellent lifespan
  • Does not impact structural performance
  • High toughness (crack and deformation-resistant)
  • Consistency in high impact and temperatures

Those are just a few of the characteristics of Hardox wear resistant plates.

AR 600 Steel Plate for Sale

AR or abrasion resistant steel plates are commonly used for construction, forestry, and mining.

AR 600 Plate
Source: Aakash Steel

The “600” defines the hardness of the plate. Therefore, it means that the AR 600 wear resistant plate has a hardness figure of 600 in the Brinell scale.

What are Wear Rings on a Centrifugal Pump?

It’s a type of wear resistant part that you attach to the impeller. This allows a bit of clearance between the casing of the pump and the impeller.

What this does is it’ll allow your pump to exceed its lifespan by preventing excessive wear.

How Are Wear Plates Used?

Since their main purpose is to prevent damage, you can add them as an overlay to your machines. Some of the most common machines that you can use wear plates on include:

  • Press Brakes
  • Shredders and Crushers
  • Heavy Lining and Moving Equipment
  • Turning and Milling Equipment
  • And Many More

If you have machines that perform heavy-duty work, installing wear plates can save them from excessive damages.

Why do Industrial Companies Need Wear Plates?

Manufacturing or industrial companies would highly make use of wear plates because of their processes.

Industrial Companies
Source: Marketing Relationship

Most of the machines their industry are performing heavy-duty work, so they need wear plates to lengthen the lifespan of their machines.

Are There Different Types of Wear Plates?

Yes, you can use different types of wear plates.

Types of Wear Plates
Source: Europages

You can select them based on the specific use you need. The different types of wear plates are, but not limited to:

  • 4140QT
  • 4340QT
  • C954 Aluminum Bronze
  • AR400
  • AR500

You’ll find these the most common types of wear plates, but there are other types out in the market.

What are the Materials of a Wear Plate?

There are many materials that comprise wear plates. However, the most common materials that complete it are:

Materials of Wear Plates
Source: Kubes Alloys

  • Hardened Materials (4140, D2, S7, 1045)
  • Abrasion Resistant Grades (A514, AR400, and AR500)

What is AR in Steel?

The definition of AR is simply Abrasion Resistant. It is a type of steel plate, which is harder because it has more carbon levels.

Abrasion Resistant
Source: Leeco Steel

What is the Difference Between AR400 and AR500?

AR stands for Abrasion Resistant; but AR400 and AR500 are two different plates. AR400 is a type of an alloy steel high in carbon.

AR400 and AR500
Source: Steel Plates Supplier

It is specifically designed to make parts and components resistant to abrasion and wear.

AR500, on the other hand, has a medium carbon level. Unlike the AR400, the AR500 is most often used for resistance and toughness.

If you need a wear plate for an armored van, mining, manufacturing, and the like, AR500 is the wear plate for you.

What Makes AR500 Strong?

AR500 is known to have a high Brinell Hardness Number (BRN).

AR500 Strong
Source: GNE Steels

What makes AR500 so strong is t that it’s made with approximately 0.31% of carbon and it is packed with iron.

What are Chromium Carbide Overlay Plates?

Chromium Carbide Overlay or CCO, is a type of clad plate that is extra hard with high abrasion resistance.

Chromium Carbide Overlay Plates
Source: Kotlyn, Inc.

You can consider it as an effective solution for cavitation, fretting, and even erosion even in high temperatures.

Compared to other types of wear plates, CCOs are low maintenance. Ideally, you can use them up to moderate impact.

What is a Hardox Plate?

Hardox Plate
Source: IndiaMart

A Hardox plate is a type of wear-resistant steel manufactured in Sweden. It is designed to be tougher, harder, but lighter than your average AR plates.

Where Can You Use Hardox Plates?

You can use Hardox Steel and Plates for a wide range of uses.

Hardox Uses
Source: PR Newswire Asia

The high toughness and resistance it has is perfect for overlaying certain machines such as:

  • Rock Crushing Machines;
  • Conveyors
  • Dump Trucks
  • Excavation Machines
  • And Others

What is Abrasion Resistant Steel?

You might have been reading it far too long without knowing what it is. In its simplest terms, abrasion resistant steel is a kind of steel that weathers all types of damages.

Abrasion Resistant Steel
Source: Leeco Steel

Being resistant to abrasion means that it is able to resist being worn out by the weather, friction, and the like.

What are Cladded Wear Plates?

Cladded wear plates are multi-layered plates, which are either low alloy steel plate or carbon combined with a cladded material.

Cladded Wear Plates
Source: Stanvac Superon Group

Clad or cladding is an application that makes a material resistant to corrosion, scratches, and the like.

How Strong is AR400 Steel?

AR400 is a type of abrasion resistant steel that has the minimum hardness on the Brinell scale of 360.

AR400 Steel
Source: Associated Steel

It only has a nominal hardness of 400, putting it in the classification of carbon steel.

Its strength makes it efficient and effective for overlaying heavy equipment, mining, blades, and so on.

How Do You Weld a Wear Plate?

To be able to install a wear plate, it needs to be welded; and it’s not a difficult thing to do.

Welding a Wear Plate
Source: JADCO Manufacturing

In fact, you can take note of these tips so you can weld a wear plate fast and easily:

  1. Pre-heat the material where you will weld the wear plate to
  2. Take the plate and attach it based on the design wanted
  3. Weld it using the right type of welding method and material
  4. Choose the correct and the most appropriate filler metal
  5. For new equipment, it is advisable to use wire indoors

Where can You Purchase Wear Plates?

You can purchase wear plates from a lot of manufacturers in the market.

But, the best production lines and manufacturers can be found in China.

Chinese Wear Plate Manufacturers

Chinese manufacturers of wear resistant plates have been one of the most trusted worldwide.

Because of the innovation and the affordability, Chinese manufacturers have been the favorite.

You can find many manufacturers of wear plates in the country, but the best is none other than us here at Waldun.

Wear Plate Prices and Rates

The rates and the prices of wear plates would depend on your manufacturer. Here with us at Waldun, we can guarantee you a cheap and an inexpensive rate.

Choosing Waldun can help you specify and customize the wear plate that you need!

Just tell us the specifics of the wear resistant plate you’ve been eyeing on and we’ll craft it for you!

Finding the Best Wear Plate Manufacturer

Years have passed and other manufacturers have never overtaken Waldun when it comes to wear plates.

Our skill and precision in creating and manufacturing wear resistant plates exceed the normal.

  • We’re ISO 9001 and ISO 14001 certified
  • Our products and services are accepted globally
  • You can get a free sample of the wear plate you need
  • We don’t require a Minimum Order Quantity (MoQ)
  • You can choose the packaging of all our products

If you’ve been looking for the best and the highest quality of wear plates, choose Waldun! We’re always ready to help you with what you need, wherever you are!

Buyer’s Guide for Wear Plates

Heavy and industrial equipment are the most subject to wear, because of their functions. How do you enhance the longevity of your machinery?

There are a lot of ways you can do to improve your machines’ durability.

But part of the best and the most proven would be the depositing of wear-resistant materials to your parts.

In this post, we will cover everything you need to know before you purchase wear plates.

We will be discussing everything from the types of wear plates you need, what makes a wear plate good, and so on, so stay tuned.

Understanding Wear Plates

Wear-resistant plates are every company’s dream. They add style to a part or a component, and it keeps it from being worn out too.

Understanding Wear Plates
Source: United Welding Force AU

Ideally, rotating and moving equipment would find the most use for it.

Why? Because of their actions and their movement. Movement is the number one culprit for damages, breakages, and the like.

You would want to them to your parts and your components because of the following things:

  • You’re aiming for restoration
  • Reduction of wear and abrasion
  • Prevention of breaking because of high impact and stress

Which Industries Can Use Wear-Resistant Plates?

The top industry that would find the best use of wear plates would be the construction industry.

Industries That Use Wear Resistant Plates
Source: Sidastico

Because of high and heavy impact, their machines tend to break faster.

However, they’re not the sole industry that needs wear plates. In fact, they can also be used by other industries, too, including:

  • Industrial Planting Industry
  • Oil and Gas Industry
  • Chemical Industry
  • Military
  • Mining Industry
  • And Other Industries That Undergo Abrasive Works

Should You Consider Buying Wear Plates?

If you are in any industry under a lot of stress and impact, then yes, you need wear plates.

Should You Buy Wear Plates_
Source: EC&M Web

You can’t always buy a new machine when it breaks; you need to have a better solution – and it’s with wear-resistant plates.

Purchasing wear plates is the best investment you can have for your equipment.

They’ll be protected and they’ll last longer; which is better because you won’t purchase new machines every time!

Advantages You Can Get With Wear-Resistant Plates

Using wear plates can give you the following benefits and advantages:

Reduced Cost

You would not purchase equipment and machineries more often than how you’re doing it now.

This means less expenses and less costs for you!

Higher Resistance Against Wear

Your equipment wouldn’t undergo the usual wear before wear plates were installed.

With highly resistant plates, you can extend the lives of your heavy-duty machinery!

Higher Productivity

All of your machines will be working effectively and efficiently with wear plates installed.

You will have fewer less time to think about repair, maintenance, and even replacement! This means nothing but higher and better productivity for your business.

Different Types of Wear Plates

There are different types and kinds of wear plates depending on your goal.

Ceramic Liner Wear Plates

This type of wear-resistant plates is perfect for sliding abrasion and impact.

Ceramic Liner Wear Plates
Source: Pascoe Industries

Ceramic is a material that is smooth, which reduces the friction between two components.

Mineral Wear Plates

The general type of wear-resistant plates, mineral wear plates is what you imagine them.

Mineral Wear Plates
Source: Diffusion Engineers

These are the metal plates that are measured by their hardness or their toughness. Depositing them to a workpiece increase hardness, toughness, and resistance to abrasion and wear.

Low Friction Wear Plates

Last but definitely not the least would be the low friction plates.

Low Friction Wear Plates
Source: Piping Technology

These are the wear-resistant plates that you need for chemical resistance, high impact, and higher friction.

The lubrication in these types of materials is what’s making it an effective additive.

What Makes up a Good Wear-Resistant Plate?

So how do you choose a wear plate that you would purchase? What things should you look at?

Composite Materials

One thing you need to check would be the materials used.

Do the materials of the plates fit your need? Would they really be what can enhance and improve the condition of your equipment?

TIP: Select a Chromium Carbide Plate. It’s one of the toughest, as well as the most corrosion, wear, and abrasion-resistant materials today.

Weight Factor

Being wear-resistant doesn’t have to be heavy. In fact, it must be lightweight.

The plates being too heavy can do more harm than good.

Choosing a light plate adds compatibility and adaptability to the part or the component.

Reliability and Consistency

No matter how big or how complex your equipment is, wear plates should be consistent.

Choose a plate that is reliable and is flexible for your benefit. For example, if you need malleability and chemical-resistant at the same time, select a type of plate that has those properties.

TIP: Do research on a wear plate material first and find out about its “other properties.”

Deformation Chances

Some wear plates deform and reshape a certain part or component.

Unless you’re fine with that, choose a wear plate that would not because it can actually break the workpiece.

You should make it to a point to choose the best wear plate. You need to choose the material that wouldn’t compromise the performance of your machines.

Who Should You Trust?

TecknoWeld Alloys
Source: Tecknoweld Alloys

There are a dozen companies there that offer wear-resistant plates. But in choosing who you’ll be working with, keep these factors in mind:

  • Experience in the Service and the Industry
  • Quality of Machines and Equipment
  • Skill of Welders
  • Professionalism

If you’re looking for the best, the most experienced, and the most sought after – work with us here at Waldun.

Why Work With Waldun?

Waldun is the company that can change the course of your business, for the better.

Since 2005, our goal has been the same – to provide high-quality products to our clients.

Having helped hundreds of companies with their hardfacing needs, there’s no reason not to trust us. We give a free sample to our clients depending on their business needs.

Regularly Maintained Machines and Equipment

We utilize cutting-edge machineries and equipment for the manufacturing of wear plates.

From the usual mineral plates, to ceramic lining, there’s nothing we can’t do!

We Value Your Business

At Waldun, you will never think about the quality of the wear-resistant plates you’ll get because it’ll be redundant.

You can contact our previous clients about our work, we can guarantee that you’ll hear nothing but commendations.

Work with the best and never worry about where you can buy wear plates again!

WHAT IS CHROMIUM CARBIDE WEAR PLATE?

what is wear plate

What is chromium carbide wear plate: CCO wear plates made a great economical replacement invention,its wear-resistant chromium carbide alloys with 4.5 to 5% carbon added to sturdy carbon steel substrates.

However, various significant refinements and strategies have occurred. And as of present, the range of overlay plate accessible includes chromium and tungsten carbide grades, which possess excellent resistance to abrasion, impact, and erosion even at both ambient and elevated temperatures. Meanwhile, in the more significant part of critical abrasion surroundings, the chromium carbide alloys are the primary profitable solution.

What is Chromium Carbide Wear Plate Alloy Chemistry

Wear Plate Image

The highest ordinary used alloy facing is a high chromium iron consists of precisely 1/3 of Chromium and in surplus of 4% combined carbon.

You are making this to correlate to WALDUN WED100 CCO plate with the chemistry of Chromium of 34.0%, carbon of 5.4%, Manganese of 3.5%, and the others at 1.3%, Balance Fe.

Meanwhile, this standard alloy can be changed in many different ways; it can improve the abrasion resistance while lowering the toughness, or the other way round. On the contrary, the matrix can be made harder by reducing the manganese to 1%, with some reduction in firmness. Also, further refinement may be accomplished by the addition of other alloying elements.

Carbides

The substance that provides high chromium powder alloys with their capability to withstand abrasion is the establishment of primary carbides from a chemical compound of iron, Chromium, and carbon, or iron, Chromium, or carbide, which is also known as chromium carbide. Pure, high rate chromium carbide can be manufactured; however, it is costly for large-area preservation, so WALDUN makes use of mixed carbide, which involves both Chromium and iron. This makes up the primary carbide with the formula M7C3, where M specifies the mixture of metal and Chromium in the compound.

Hardness

A standard (WED100) overlay alloy consists of a compound of chromium carbides in a matrix of a chromium iron-carbon alloy. The hardness of primary chromium carbides is proportionate of 1700HV correlate with. For instance, ordinary workshop steel files, with firmness of 600HV. In general, the hardness of these alloys can be calculated using a Rockwell hardness tester. Even though it neither measures the carbide or the matrix, it gives an agreeable general proof of the hardness of the alloy. An average value of being 54-60 HRc.

Microstructure

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.

Different chemical properties are shown below.

Chemical Analysis

Carbon 2.88% Chromium 16.70%
Manganese 2.03% Molybdenum less than 0.5%
Silicon 0.37% Boron 0.62%

The primary carbides which can be recognized by their crystalline arrangement. Hence, when cutting via a perpendicular plane, they take the shape of hexagonal. Not minding the angle of the cut, the primary carbides always form with a black cavity close to the middle, have sharp corners, and are well established with structures towards the dark matrix background.

This micrograph reveals an alloy of the lower optimum compound with no clear visibility for primary carbide structures. Most of the chromium content has clear visibility as white specks in the matrix. Lower carbides appear as the round or fish-bone pattern. Thus, this type of alloy is most appropriate for high impact implementation.

Chemical Analysis

Carbon 3.88% Chromium 26.40%
Manganese 2.55% Molybdenum less than 0.5%
Silicon 0.51% Boron less than 0.5%

Improving the carbon and chromium content leads to the formation of primary carbide structures, which takes shape as lighter hexagonal forms in a darker matrix.

Take note of the clear visible cavity inside each crystalline-arranged primary carbide.

Chemical Analysis

Carbon 4.88% Chromium 29.20%
Manganese 3.20% Molybdenum less than 0.05%
Silicon 0.43% Boron less than 0.5%

Meanwhile, this particular sample is the first that align within the advisable 4%to 5% carbon range, which indicates preferable primary carbide development. The arranged structures are well differentiated with ease from the dark matrix, with a perfect view of the display of primary carbides cut crosswise (it has smaller hexagonal shapes), lengthwise (it has the lengthy needle-like way, middle), and transversely (top right corner, having the hollow center represented as an elongated cavity). In addition, the density of the carbides, which occurs within the matrix material, is found at the lower end of the recommended 35% to 35% range.

Chemical Analysis

Carbon 4.78% Chromium 32.00%
Manganese 3.34% Molybdenum less than 0.05%
Silicon 0.47% Boron less than 0.5%

However, this micrograph exhibits the primary carbides as well defined and clear visibility occurring within the dark matrix substance. Also, rests assured that the elongated display of the middle cavity of each primary carbide crystalline structural arrangement when it is cut at an angle. The density is perfect within the recommended 35% to 45% range, with equal distribution, which helps give outstanding wear characteristics.

Chemical Analysis

Carbon 4.84% Chromium 31.60%
Manganese 3.09% Molybdenum less than 0.5%
Silicon 0.46% Boron less than 0.5%

Meanwhile, in this last sample, the primary carbide structures are at their highest density, which is within the range of 35% to 45% — thereby forming an alloy with the highest wear resistance without dealing with too much brittleness. Also, there is still an available ample matrix substance to hold the primary carbides in place. However, with the patterns of crystalline development at right angles, which can be seen with ease, alongside with the characteristics hexagonal crosscut shapes. Also, the overall ways in the form of needle-like and every one of them have a central cavity.

Take Note:

View the WALDUN Plate scope, and it gives comprehensive details of the properties of each alloy formulation and its appropriateness for specific service conditions.

What is chromium carbide wear plate appearance

Chromium Carbide Overlay Plates

The appearance of an overlay wear plate doesn’t indicate it’s resistance to wear. But it is mostly the less cosmetically appealing substances that have the proper mechanical properties.

However, when the carbon content of the overlay moves beyond the 4% range, then the facing becomes more and more viscous, which gravitates to be kind of uneven. However, it may still have some small holes, which happens to be elongated down to the base plate. For the majority uses, this absence of smoothness is insignificant.

Therefore, if a smooth surface finish is significant; for instance, when substance flow is analytical, more continuous surfaces can be manufactured by the use of the submerged arc welding process to deposit the overlay.

Cracks

The presence of stress relief cracks is one more feature of a high-quality plate. Hence, this is different from the earliest perception, are even favorable to this material. The appearance of cracks in the hardfacing, at the proper frequency and spacing, enables the plate to be rolled, formed, and bent free from any impairment. Moreover, this feature is one of the critical trademarks of WALDUN’sWALDUN’s hardfaced plate patents.

What is Basic Applications

cement-plant

In applications, WALDUN WED200 common purpose chromium carbide overlay plate usually can provide up to a maximum of 20 times the life of carbon steel. Combined with its multiple purpose characteristics, this is the main aim why WED200 plate has become a great cost savings in the production of glass, aluminum, cement, asphalt, power, petrochemicals, pulp and paper, mining, steel and synfuels, as well as in dredging, oil refining, food and refuse processing, and many material-handling applications, such as scrape and steel recycling.

The steel manufacturing industry, for instance, needs to wear protection for hoppers, conveyor liners, and grizzly bears that fast wear away without hardfacing protection.

Hence in mining, the absence of hardfacing protection, critical components, for example, front-end loader liners, chute liners, and wear pads lose before the usual time their functionality due to the effect of silicious matter.

Moreover, the refuse processing plants make use of overlay products in their hydra- pulper liners and beaters, fan blades and liners, conical section wear liners, screw conveyors and troughs, baler liners, tub liners, flop gates, ash removal systems, and transfer points.

How Do You Order Wear Plates?

You can order wear plates the same way as how you order other pieces or parts for your machines.

If you have a company in mind, you can contact them via their email address or their hotline.

To make transactions easier, you can include everything in your email including:

  • The type of your business
  • The amount of wear plates you’re going to order; and
  • Region where your business is

Where Can You Buy a Wear Plate?

You can purchase wear plates from many different companies from around the world. But we here at Waldun will be able to accommodate to your needs.

We can provide and install abrasion resistant wear plates for your machineries or your equipment.

Get A Quote Now !