Abrasion Resistant Overlay Plate

Abrasion Resistant 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 through welding overlay technology. It is widely used in mining, cement, power generation, steel plants, 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, impact, and particle erosion.

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. High Surface Hardness

The wear-resistant layer typically achieves:

• 55–65 HRC hardness
• 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:

• Hard overlay layer (wear resistance)
• 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, ensuring:

• Uniform wear resistance
• Stable mechanical performance
• Reduced localized failure

Types of Wear Resistance

Abrasion Resistant Overlay Plate is designed to resist multiple wear mechanisms:

• Sliding abrasion: caused by continuous material movement across the surface
• Impact abrasion: caused by falling or striking materials
• Erosive wear: caused by high-speed particle flow
• Gouging wear: caused by large particle scraping

Performance Comparison

Property	Overlay Plate	Standard Carbon Steel	Wear Resistant Steel
Surface Hardness	Very High	Low	Medium–High
Abrasion Resistance	Excellent	Poor	Good
Impact Resistance	Medium	High	High
Service Life	Very Long	Short	Long

Key Factors Affecting Wear Performance

Alloy Composition

Higher chromium and carbon content increase carbide formation and improve wear resistance.

Overlay Thickness

Thicker wear layers provide longer service life under severe abrasion conditions.

Carbide Distribution

Uniform carbide dispersion ensures consistent wear performance across the surface.

Welding Process Control

Heat input and cooling rate affect hardness, crack resistance, and microstructure stability.

Typical Industrial Applications

Abrasion Resistant Overlay Plates are widely used in:

• Mining equipment liners
• Cement plant chutes and hoppers
• Coal handling systems
• Power plant ash systems
• Steel mill conveyors
• Crusher and screening equipment
• Excavator buckets and dump trucks
• Bulk material transfer systems

Advantages in Industrial Use

• Extremely high resistance to abrasive wear
• Long service life under harsh conditions
• Reduced maintenance and downtime
• Customizable overlay composition
• Strong metallurgical bonding with base plate