Placa de sobreposição de solda

Weld 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 plate using advanced welding overlay techniques. É amplamente utilizado na mineração, cimento, geração de energia, usinas siderúrgicas, and bulk material handling industries where severe abrasion and impact conditions are present.

The performance of weld overlay plate depends heavily on the quality of the welding process, which determines the hardness, bonding strength, and wear resistance of the surface layer.

Overview of Weld Overlay Process

The weld overlay process is a surface engineering method that applies a wear-resistant alloy layer onto a steel substrate through controlled welding techniques. The process creates a strong metallurgical bond between the base metal and the overlay layer.

Main Welding Overlay Methods

1. Soldagem a arco aberto (SERRA / FCAW Overlay)

This is the most commonly used industrial method for producing weld overlay plates.

• Uses flux-cored wire or submerged arc welding
• Alta taxa de deposição
• Suitable for large-area production
• Produces uniform chromium carbide layers

Vantagens:

• High efficiency
• Stable welding quality
• Cost-effective for mass production

2. Shielded Metal Arc Overlay (SMAW)

A manual welding method used for smaller components or repair work.

• Uses coated electrodes
• Flexible operation
• Suitable for complex shapes

Vantagens:

• Low equipment requirement
• Good for repair and maintenance

Limitações:

• Lower efficiency compared to automated processes

3. Soldagem a arco de metal a gás (GMAW / MIG Overlay)

A semi-automatic or automatic process.

• Uses continuous wire feeding
• Controlled shielding gas environment
• Good surface quality

Vantagens:

• Stable arc
• Good control of dilution
• Suitable for medium-scale production

4. Arco Transferido por Plasma (ATP) Soldagem

A high-precision overlay method.

• Concentrated arc energy
• Very low dilution rate
• High-quality wear-resistant layer

Vantagens:

• Excellent hardness control
• Ligação metalúrgica forte
• Ideal for high-performance wear parts

Key Stages of Weld Overlay Manufacturing

1. Preparação da Placa Base

• Cleaning oil, ferrugem, e impurezas
• Surface grinding or shot blasting
• Ensuring proper welding surface condition

2. Pré-aquecimento (if required)

• Reduces thermal stress
• Prevents cracking in high-carbon or thick plates
• Typically used for thick base materials

3. Soldagem de sobreposição

• Deposition of wear-resistant alloy layer
• Controlled heat input
• Multi-layer welding for thick overlays

4. Cooling Process

• Controlled cooling to avoid cracking
• Prevents residual stress accumulation
• Ensures stable microstructure formation

5. Post-Weld Treatment

• Surface leveling or grinding
• Inspection of hardness and bonding quality
• Dimensional correction if required

Formação de Camada Resistente ao Desgaste

Durante a soldagem, alloying elements such as chromium and carbon form hard carbide structures:

• Cr₇C₃
• Cr₂₃C₆

These carbide phases are evenly distributed in the weld matrix, creating a highly wear-resistant surface.

Key Process Control Factors

Fator	Influence
Heat Input	Controls hardness and dilution
Welding Speed	Affects layer uniformity
Cooling Rate	Determines crack resistance
Composição da liga	Defines wear resistance level
Layer Thickness	Impacts service life

Advantages of Weld Overlay Plate

• Extremely high surface hardness (55–65 HRC)
• Strong metallurgical bonding to base plate
• Customizable wear resistance performance
• Longa vida útil em ambientes abrasivos
• Suitable for large-scale industrial production

Aplicações Típicas

Weld overlay plates are widely used in:

• Forros de equipamentos de mineração
• Calhas e tremonhas para fábricas de cimento
• Sistemas de manuseio de carvão
• Sistemas de cinzas para usinas de energia
• Peças de desgaste de usinas siderúrgicas
• Crusher and conveyor systems
• Bulk material transfer equipment