Placa de desgaste revestida
UM 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, rolando, 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, cimento, aço, and bulk material handling industries where both abrasion and impact are extremely severe.
- Descrição
UM 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. É amplamente utilizado na mineração, cimento, usinas siderúrgicas, usinas de energia, 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:
- Camada base: carbon steel or structural steel (for strength and support)
- Cladding layer: high-hardness alloy (para resistência ao desgaste)
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 (Revestimento duro)
This is the most common process.
Princípio do Processo:
A wear-resistant alloy is deposited onto the steel surface using welding.
Typical Methods:
- Soldagem a arco fluxado (FCAW)
- Soldagem por arco submerso (SERRA)
- Soldagem a arco aberto
Cladding Materials:
- Chromium carbide alloys
- High chromium iron alloys
- Martensitic wear-resistant alloys
Principais recursos:
- Strong metallurgical bond
- Resistência ao desgaste muito alta
- Suitable for thick wear layers
2. Explosion Bonding (Explosive Cladding)
A high-energy bonding process using controlled explosive force.
Princípio do Processo:
- Two metal layers are accelerated at high speed
- High-pressure impact creates a metallurgical bond
Principais recursos:
- Extremely strong bonding strength
- No melting of base material
- Suitable for large plates
Limitações:
- Higher cost
- Limited thickness control
3. Hot Rolling Cladding
A solid-state bonding process performed under high temperature and pressure.
Princípio do Processo:
- Base plate and cladding layer are heated
- Rolled together under high pressure
Principais recursos:
- Uniform bonding
- Large-scale industrial production
- Good surface quality
4. Revestimento a Laser (Advanced Process)
A modern precision coating method.
Princípio do Processo:
- Laser melts a small area of base surface
- Powdered alloy is added and fused
- Forms a metallurgically bonded layer
Principais recursos:
- Alta precisão
- Low dilution rate
- Excelente resistência ao desgaste e à corrosão
- Suitable for high-value components
5. Revestimento por pulverização térmica (Less Common for Plates)
Process Types:
- HVOF (Combustível de oxigênio de alta velocidade)
- Pulverização de plasma
Principais recursos:
- No deep metallurgical bonding
- Thin coating layer
- Lower cost but weaker bond strength
Structure of Clad Wear Plate
| Camada | Função |
|---|---|
| Camada Hardfacing | Resistência ao desgaste |
| Transition zone | Bonding interface |
| Base steel | Strength and impact resistance |
This structure allows the plate to handle both abrasion and structural load.
Características de desempenho
| Propriedade | Desempenho |
|---|---|
| Resistência ao desgaste | Extremamente alto |
| Resistência ao impacto | Bom (base dependent) |
| Bond Strength | Alto (weld/explosion/roll) |
| Dureza | 55–65+ HRC (camada superficial) |
| Vida útil | 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
- Absorve energia de impacto
- Prevents cracking and failure
3. Composite Design Advantage
- Combines hardness + toughness in one plate
- Optimized for severe working conditions
Common Industrial Applications
Indústria Mineira
- Revestimentos do britador
- Revestimentos de tremonha
- Baldes de escavadeira
- Ore chutes
Indústria de cimento
- Revestimentos para moinhos
- Kiln inlet/outlet liners
- Sistemas de transferência de materiais
Indústria Siderúrgica
- Equipamento para planta de sinterização
- Sistemas de manuseio de coque
- Conveyor wear plates
Usinas Elétricas
- Sistemas de manuseio de carvão
- Ash pipelines
- Wear-resistant ducts
Manuseio de materiais a granel
- Forros de caminhão
- Funis de armazenamento
- Calha de alimentação
Advantages of Clad Wear Plates
- Resistência ao desgaste extremamente alta
- 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
Limitações
- Higher cost than standard AR steel
- Welding requires special procedures
- Surface layer is not easily machined
- Not suitable for precision forming after cladding
