Abrasion Resistant Overlay Plate
Abrasion Resistant Overlay Plate delivers superior wear resistance through a combination of high-hardness chromium carbide formation and a tough steel backing structure. Its ability to withstand sliding, dampak, and erosive wear makes it an essential material for heavy-duty industrial applications where long-term durability and reliability are required.
- Keterangan
Pelat Overlay Tahan Abrasi adalah produk baja komposit tahan aus yang diproduksi dengan mendepositkan lapisan paduan kekerasan tinggi ke dasar baja karbon atau baja paduan rendah melalui teknologi overlay pengelasan.. Ini banyak digunakan di pertambangan, semen, pembangkit listrik, pabrik baja, and bulk material handling systems where severe abrasive conditions occur.
The key value of this material lies in its exceptional ability to resist surface material loss caused by friction, dampak, dan erosi partikel.
Wear Resistance Principle
The abrasion resistance of overlay plate is achieved through a combination of hard alloy phases and a tough supporting base.
1. Hard Carbide Reinforcement
The overlay layer contains high levels of chromium and carbon, which form extremely hard carbide phases such as:
- Cr₇C₃
- Cr₂₃C₆
These carbide particles act as rigid barriers that resist cutting and grinding from abrasive materials.
2. Kekerasan Permukaan Tinggi
The wear-resistant layer typically achieves:
- 55–65 kekerasan HRC
- High microhardness in carbide-rich zones
This significantly reduces surface material removal during friction and impact.
3. Dual-Layer Structure Support
The structure consists of:
- Lapisan overlay keras (ketahanan aus)
- Tough base steel (impact absorption)
The base plate prevents cracking and deformation under mechanical load, while the overlay resists surface wear.
4. Controlled Microstructure
The weld overlay process produces a controlled distribution of carbides within a metallic matrix, memastikan:
- Uniform wear resistance
- Stable mechanical performance
- Reduced localized failure
Types of Wear Resistance
Abrasion Resistant Overlay Plate is designed to resist multiple wear mechanisms:
- Abrasi geser: caused by continuous material movement across the surface
- Abrasi dampak: caused by falling or striking materials
- Erosive wear: caused by high-speed particle flow
- Gouging wear: caused by large particle scraping
Perbandingan Kinerja
| Milik | Pelat Hamparan | Baja Karbon Standar | Baja Tahan Aus |
|---|---|---|---|
| Kekerasan Permukaan | Sangat Tinggi | Rendah | Sedang–Tinggi |
| Ketahanan Abrasi | Bagus sekali | Miskin | Bagus |
| Resistensi Dampak | Sedang | Tinggi | Tinggi |
| Kehidupan Pelayanan | Sangat lama | Pendek | Panjang |
Key Factors Affecting Wear Performance
Komposisi paduan
Higher chromium and carbon content increase carbide formation and improve wear resistance.
Ketebalan overlay
Thicker wear layers provide longer service life under severe abrasion conditions.
Carbide Distribution
Uniform carbide dispersion ensures consistent wear performance across the surface.
Kontrol Proses Pengelasan
Masukan panas dan laju pendinginan mempengaruhi kekerasan, ketahanan retak, dan stabilitas struktur mikro.
Aplikasi Industri Khas
Abrasion Resistant Overlay Plates are widely used in:
- Liner peralatan pertambangan
- Peluncuran dan hopper pabrik semen
- Sistem penanganan batubara
- Sistem abu pembangkit listrik
- Steel mill conveyors
- Peralatan penghancur dan penyaringan
- Ember ekskavator dan dump truck
- Sistem transfer material massal
Keuntungan dalam Penggunaan Industri
- Extremely high resistance to abrasive wear
- Umur panjang dalam kondisi yang keras
- Mengurangi pemeliharaan dan waktu henti
- Komposisi overlay yang dapat disesuaikan
- Ikatan metalurgi yang kuat dengan pelat dasar
