Clad Wear Plate

Pelat Keausan Berpakaian

Pelapis Tahan Aus Untuk Baja Pelapis Tahan Aus Untuk Baja
Baja Tahan Aus Tinggi Baja Tahan Aus Tinggi

A clad wear plate is an advanced composite wear-resistant material produced by bonding a high-hardness alloy layer onto a structural steel base using welding, explosion bonding, bergulir, or laser cladding processes.

Compared with solid AR steels, clad plates offer significantly higher wear resistance while maintaining structural toughness. The combination of a hard surface layer and a tough base makes them ideal for mining, semen, baja, and bulk material handling industries where both abrasion and impact are extremely severe.

Kategori:

A clad wear plate is a composite abrasion-resistant steel plate manufactured by bonding a high-hardness wear-resistant layer onto a carbon steel or low-alloy steel base plate. Ini banyak digunakan di pertambangan, semen, pabrik baja, pembangkit listrik, and bulk material handling systems where extreme wear and impact conditions exist.

Unlike solid AR steels (such as AR400 or AR500), clad wear plates achieve wear resistance through a surface overlay layer, while the base plate provides strength and toughness.

What Is a Clad Wear Plate?

A clad wear plate typically consists of two main layers:

  • Lapisan dasar: carbon steel or structural steel (for strength and support)
  • Cladding layer: high-hardness alloy (untuk ketahanan aus)

The two layers are metallurgically or mechanically bonded to act as a single plate.

Main Manufacturing Processes of Clad Wear Plates

1. Weld Overlay Cladding (menghadapi keras)

This is the most common process.

Prinsip Proses:

A wear-resistant alloy is deposited onto the steel surface using welding.

Typical Methods:

  • Pengelasan busur berinti fluks (Fcaw)
  • Pengelasan busur terendam (GERGAJI)
  • Pengelasan busur terbuka

Cladding Materials:

  • Chromium carbide alloys
  • High chromium iron alloys
  • Martensitic wear-resistant alloys

Fitur Utama:

  • Strong metallurgical bond
  • Ketahanan aus yang sangat tinggi
  • Suitable for thick wear layers

2. Explosion Bonding (Explosive Cladding)

A high-energy bonding process using controlled explosive force.

Prinsip Proses:

  • Two metal layers are accelerated at high speed
  • High-pressure impact creates a metallurgical bond

Fitur Utama:

  • Extremely strong bonding strength
  • No melting of base material
  • Suitable for large plates

Batasan:

  • Biaya lebih tinggi
  • Limited thickness control

3. Hot Rolling Cladding

A solid-state bonding process performed under high temperature and pressure.

Prinsip Proses:

  • Base plate and cladding layer are heated
  • Rolled together under high pressure

Fitur Utama:

  • Uniform bonding
  • Large-scale industrial production
  • Good surface quality

4. Pelapisan Laser (Advanced Process)

A modern precision coating method.

Prinsip Proses:

  • Laser melts a small area of base surface
  • Powdered alloy is added and fused
  • Forms a metallurgically bonded layer

Fitur Utama:

  • Presisi tinggi
  • Low dilution rate
  • Ketahanan aus dan korosi yang sangat baik
  • Suitable for high-value components

5. Lapisan Semprot Termal (Less Common for Plates)

Process Types:

  • HVOF (Bahan Bakar Oksigen Kecepatan Tinggi)
  • Penyemprotan plasma

Fitur Utama:

  • No deep metallurgical bonding
  • Thin coating layer
  • Lower cost but weaker bond strength

Structure of Clad Wear Plate

Lapisan Fungsi
Lapisan permukaan keras Ketahanan aus
Transition zone Bonding interface
Baja dasar Strength and impact resistance

This structure allows the plate to handle both abrasion and structural load.

Karakteristik Kinerja

Milik Pertunjukan
Ketahanan Aus Sangat Tinggi
Resistensi Dampak Bagus (base dependent)
Bond Strength Tinggi (weld/explosion/roll)
Kekerasan 55–65+ HRC (lapisan permukaan)
Kehidupan Pelayanan 3–10× carbon steel

Why Clad Wear Plates Have Excellent Wear Resistance

1. Hard Alloy Surface Layer

  • High chromium carbides or alloy phases
  • Strong resistance to cutting and abrasion

2. Tough Base Steel Support

  • Absorbs impact energy
  • Prevents cracking and failure

3. Composite Design Advantage

  • Combines hardness + toughness in one plate
  • Optimized for severe working conditions

Common Industrial Applications

Industri Pertambangan

  • Lapisan penghancur
  • Liner hopper
  • Ember ekskavator
  • Ore chutes

Industri Semen

  • Liner pabrik penggilingan
  • Kiln inlet/outlet liners
  • Sistem perpindahan material

Industri Baja

  • Peralatan pabrik sinter
  • Sistem penanganan kokas
  • Pelat keausan konveyor

Pembangkit Listrik

  • Sistem penanganan batubara
  • Ash pipelines
  • Saluran tahan aus

Penanganan Material Massal

  • Liner truk
  • Hopper penyimpanan
  • Saluran pakan

Advantages of Clad Wear Plates

  • Ketahanan aus yang sangat tinggi
  • Long service life in severe environments
  • Can be applied on low-cost base steel
  • Suitable for large and complex structures
  • Strong impact + abrasion performance
  • Customizable thickness and alloy layer

Batasan

  • Higher cost than standard AR steel
  • Welding requires special procedures
  • Surface layer is not easily machined
  • Not suitable for precision forming after cladding

Baja Mangan Karbon Tinggi

Baja Mangan Karbon Tinggi

Baja Mangan Karbon Tinggi