weld on wear plates
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Weld-on wear plates are an essential solution for extending the lifespan of industrial machinery operating under extreme abrasion and impact conditions. By selecting the correct processing techniques for welding, pemotongan, bending and machining, users can achieve optimal service life and structural performance.

Proper fabrication plays a critical role in maximizing durability and preventing installation-related failures, especially with high-hardness and carbide overlay wear plates.

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Weld-on wear plates are used to protect mining, penggalian, construction and industrial machinery from severe abrasion, dampak dan erosi. These plates are typically made from materials such as baja mangan, padam & tempered steel (AR400 / AR500 type), lapisan kromium karbida (CCO) piring, and hardfacing steel. They are welded directly onto high-wear surfaces to significantly extend equipment service life.

To ensure proper installation and performance, weld-on wear plates require specific processing and fabrication techniques, depending on the material hardness, thickness and structural application.

Common Processing Methods for Weld-On Wear Plates

1. Pengelasan

Welding is the primary method for attaching wear plates onto machinery surfaces.

Typical Welding Methods

  • mma / Tongkat Pengelasan (SMAW)

  • AKU / MAG Welding (GMAW)

  • Flux-Cored Welding (Fcaw)

  • Pengelasan Busur Terendam (GERGAJI) (for thicker plates or CCO plates)

Key Welding Considerations

  • Preheating may be required depending on hardness and thickness

  • Low hydrogen welding consumables recommended to prevent cracking

  • Manganese steel requires no post-weld heat treatment but work-hardens during service

  • Chromium carbide overlay plates are welded on substrate side only, not on carbide surface

2. Pemotongan

Wear plates can be cut using thermal or mechanical cutting processes.

Metode Pemotongan Bahan yang Cocok Catatan
Pemotongan Plasma baja AR, CCO Presisi tinggi, smooth finish
Pemotongan Laser 400HB and below Ideal for fine shapes
Pemotongan Bahan Bakar Oxy Thick high-strength plates Preheat recommended
Pemotongan Jet Air CCO plate, keramik Tidak ada zona yang terkena dampak panas

3. Membungkuk dan Membentuk

Wear plates used in hoppers, air terjun, pipes or buckets often require bending.

Bending Requirements

  • High-strength steels (AR400/AR500) require large bending radii

  • Preheating improves flexibility and reduces cracking risk

  • CCO plates should be bent with overlay facing outside

  • Manganese steel bends easily due to high ductility

4. Machining and Drilling

Wear plates can be drilled or machined, but may require special tools.

Jenis Bahan kemampuan mesin Catatan
Baja Mangan Sulit Work-hardens rapidly; carbide tools required
AR Steels Sedang Slow speed, high feed, coolant required
Pelat CCO Not machinable surface Drill only through base plate
Ceramic Composites Generally not drilled Use mechanical fastening instead

5. Hardfacing and Surface Overlaying

For repair applications, additional layers of wear protection can be welded directly on-site using hardfacing electrodes or wires.

Typical Hardfacing Solutions

  • Chromium carbide weld layer

  • Permukaan keras tungsten karbida

  • Nickel-based impact-resistant overlay

Applications include rebuilding bucket edges, crusher teeth, and scraper blades.

Typical Industries Using Weld-On Wear Plates

  • Mining and quarry crushing equipment

  • Excavator, loader and bulldozer bucket protection

  • peluncuran, hoppers and conveyor system liners

  • Dump truck bodies and dozer blades

  • Mixing and screening machinery

  • Recycling and metal shredding machines

mengelas pada pelat aus

mengelas pada pelat aus

mengelas pada pelat aus

mengelas pada pelat aus

mengelas pada pelat aus