لوحة تراكب اللحام

Weld Overlay Plate is a composite wear-resistant steel product manufactured by depositing a high-hardness alloy layer onto a carbon steel or low-alloy steel base plate using advanced welding overlay techniques. ويستخدم على نطاق واسع في التعدين, أسمنت, توليد الطاقة, مصانع الصلب, and bulk material handling industries where severe abrasion and impact conditions are present.

The performance of weld overlay plate depends heavily on the quality of the welding process, which determines the hardness, bonding strength, and wear resistance of the surface layer.

Overview of Weld Overlay Process

The weld overlay process is a surface engineering method that applies a wear-resistant alloy layer onto a steel substrate through controlled welding techniques. The process creates a strong metallurgical bond between the base metal and the overlay layer.

Main Welding Overlay Methods

1. اللحام بالقوس المفتوح (رأى / FCAW Overlay)

This is the most commonly used industrial method for producing weld overlay plates.

• Uses flux-cored wire or submerged arc welding
• ارتفاع معدل الترسيب
• Suitable for large-area production
• Produces uniform chromium carbide layers

المزايا:

• High efficiency
• Stable welding quality
• Cost-effective for mass production

2. Shielded Metal Arc Overlay (SMAW)

A manual welding method used for smaller components or repair work.

• Uses coated electrodes
• Flexible operation
• مناسبة للأشكال المعقدة

المزايا:

• Low equipment requirement
• Good for repair and maintenance

القيود:

• Lower efficiency compared to automated processes

3. لحام القوس المعدني بالغاز (GMAW / MIG Overlay)

A semi-automatic or automatic process.

• Uses continuous wire feeding
• Controlled shielding gas environment
• نوعية سطح جيدة

المزايا:

• Stable arc
• Good control of dilution
• Suitable for medium-scale production

4. قوس البلازما المنقول (منطقة التجارة التفضيلية) لحام

A high-precision overlay method.

• Concentrated arc energy
• Very low dilution rate
• High-quality wear-resistant layer

المزايا:

• Excellent hardness control
• رابطة معدنية قوية
• Ideal for high-performance wear parts

Key Stages of Weld Overlay Manufacturing

1. إعداد لوحة القاعدة

• Cleaning oil, الصدأ, والشوائب
• Surface grinding or shot blasting
• Ensuring proper welding surface condition

2. التسخين (if required)

• Reduces thermal stress
• Prevents cracking in high-carbon or thick plates
• Typically used for thick base materials

3. لحام التراكب

• Deposition of wear-resistant alloy layer
• Controlled heat input
• Multi-layer welding for thick overlays

4. Cooling Process

• Controlled cooling to avoid cracking
• Prevents residual stress accumulation
• Ensures stable microstructure formation

5. معالجة ما بعد اللحام

• Surface leveling or grinding
• Inspection of hardness and bonding quality
• Dimensional correction if required

تشكيل طبقة مقاومة للاهتراء

أثناء اللحام, alloying elements such as chromium and carbon form hard carbide structures:

• Cr₇C₃
• Cr₂₃C₆

These carbide phases are evenly distributed in the weld matrix, creating a highly wear-resistant surface.

Key Process Control Factors

عامل	Influence
Heat Input	Controls hardness and dilution
Welding Speed	Affects layer uniformity
Cooling Rate	Determines crack resistance
تكوين السبائك	Defines wear resistance level
Layer Thickness	Impacts service life

Advantages of Weld Overlay Plate

• صلابة سطحية عالية للغاية (55-65 لجنة حقوق الإنسان)
• Strong metallurgical bonding to base plate
• Customizable wear resistance performance
• Long service life in abrasive environments
• Suitable for large-scale industrial production

التطبيقات النموذجية

Weld overlay plates are widely used in:

• بطانات معدات التعدين
• مزالق مصنع الأسمنت والقواديس
• أنظمة معالجة الفحم
• أنظمة رماد محطة توليد الكهرباء
• أجزاء ارتداء مصنع الصلب
• Crusher and conveyor systems
• Bulk material transfer equipment