Chromium Carbide Wear Plate
The manufacturing of Chromium Carbide Wear Plates involves:
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Selecting a tough steel base
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Preparing a high-hardness chromium carbide overlay
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Depositing the overlay using controlled welding processes
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Heat treatment and stress relief
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Surface finishing and strict quality inspection
- Description
Chromium Carbide Wear Plates (CCO Plates) are bimetallic steel plates designed for extreme abrasion and impact resistance.
They consist of a high-hardness chromium carbide overlay layer welded onto a tough steel base, combining:
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Exceptional surface hardness (58–65 HRC)
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Impact toughness from the base steel
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Long service life in mining, cement, power, and material handling industries
The key to producing a reliable CCO plate lies in precision overlay welding and quality control.
Manufacturing Process of Chromium Carbide Wear Plates
1. Base Plate Selection
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Common base steels: Q235, S355, NM400, AR400/450
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The base provides structural strength, toughness, and weldability.
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Thickness is chosen according to application requirements (typically 6–50 mm).
2. Overlay Material Preparation
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Overlay is typically a chromium carbide alloy wire or strip containing:
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10–30% chromium (Cr)
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2–5% carbon (C)
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Optional additions: Ni, Mo, Fe
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The overlay provides hardness and abrasion resistance, forming a continuous carbide layer on the surface.
3. Overlay Welding Process
There are several methods to deposit the chromium carbide layer:
| Method | Description | Advantages |
|---|---|---|
| Single/Multiple Pass Submerged Arc Welding (SAW) | Large plates welded with chromium carbide wire in several passes | High deposition rate, uniform overlay |
| Plasma Transferred Arc (PTA) | High-energy plasma welds chromium carbide powder onto plate | Very high hardness and low dilution |
| Flux-Cored Arc Welding (FCAW) | Manual or semi-automatic overlay with flux-cored wire | Flexible, suitable for small or custom plates |
| Shielded Metal Arc Welding (SMAW) | Stick welding with chromium carbide rods | Simple, suitable for repair or small batches |
Key factors during welding:
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Maintain overlay thickness as designed (3–20 mm typical)
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Control dilution between overlay and base (<10–15%)
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Preheat thick base plates to 150–250°C to prevent cracking
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Multi-pass welding with controlled cooling ensures uniform hardness and metallurgical bonding
4. Heat Treatment and Stress Relief
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Some CCO plates undergo post-weld stress relief at 150–200°C
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Reduces residual stress from multi-pass welding
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Ensures dimensional stability and prevents cracking during service
5. Surface Finishing and Inspection
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Grinding or shot blasting removes slag and spatter
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Non-destructive testing (NDT) such as ultrasonic or dye penetrant inspection ensures overlay integrity
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Hardness testing is done to confirm target HRC or HBW
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Plates are cut, drilled, or prepped for shipping and installation
6. Final Quality Control
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Overlay thickness measurement (typically 3–20 mm)
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Hardness testing (surface: 58–65 HRC, base: 200–300 HBW)
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Visual and metallurgical inspection for cracks or porosity
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Ensures the plate meets industry standards for mining, cement, and heavy equipment applications
Key Advantages of the Manufacturing Process
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High wear resistance: Hard chromium carbide surface resists sliding and impact abrasion
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Durable base: Tough steel base absorbs shocks, reduces brittle failure
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Customizable thickness and size: Overlay and base tailored for application needs
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Consistent quality: Multi-pass welding and strict inspection ensure reliable performance
