Welding Wear

Welding wear technology refers to the production of composite wear-resistant parts by welding a hard alloy layer onto a steel substrate. These parts are designed to withstand abrasion, impact, and erosion in severe industrial environments while keeping high structural strength and low cost.

This technology is widely used in mining, cement, power generation, steel plants, and bulk material handling systems.

Structure of Welded Composite Wear Parts

A welding wear component is a two-layer or multi-layer composite material:

The hardfacing layer is typically rich in chromium carbide, boron, or tungsten carbide.

Welding Process for Composite Wear Parts

1. Base Material Preparation

The base steel is cleaned and prepared to ensure:

• Strong weld bonding

• No contamination

• Stable weld pool

This ensures maximum metallurgical fusion between layers.

2. Hardfacing Alloy Welding

Wear-resistant alloys are deposited onto the base steel using:

• Flux-Cored Arc Welding (FCAW)

• Submerged Arc Welding (SAW)

• Open Arc Welding (OAW)

These automated processes allow uniform thickness, controlled chemistry, and high productivity.

3. Formation of Wear-Resistant Microstructure

During welding:

• The alloy melts and solidifies

• Hard carbides form inside the overlay layer

• These carbides create an extremely hard wear surface

Typical hardness range: HRC 55–65

4. Controlled Cooling and Crack Pattern

After welding, controlled cooling creates:

• Fine, stress-relief cracks in the overlay

• These cracks prevent large structural cracking

• They improve impact and thermal stability

This is a designed micro-crack system, not a defect.

5. Cutting and Shaping

The welded plates are cut into wear parts using:

• Plasma cutting

• Laser cutting

• Water jet cutting

Then they are formed into:

• Liners

• Chute plates

• Bending segments

• Conveyor and crusher parts

Why Welding Wear Technology Is Superior

Compared with solid wear steel, welded wear parts provide:

• Much higher abrasion resistance

• Lower material cost

• Custom thickness and alloy design

• Easy repair by re-welding

• Longer service life

Typical Applications

Welded composite wear parts are used in:

• Mining chutes and hoppers

• Cement mill liners

• Coal handling systems

• Power plant ash pipes

• Steel mill conveyor systems

These environments involve high abrasion, sliding wear, and impact.