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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. Широко используется в горнодобывающей промышленности., цемент, производство электроэнергии, сталелитейные заводы, 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. Открытая дуговая сварка (ПИЛА / FCAW Overlay)

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

• Uses flux-cored wire or submerged arc welding
• Высокая скорость осаждения
• Suitable for large-area production
• Produces uniform chromium carbide layers

Преимущества:

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

2. Shielded Metal Arc Overlay (СМАВ)

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

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

Преимущества:

• Low equipment requirement
• Good for repair and maintenance

Ограничения:

• Lower efficiency compared to automated processes

3. Газовая дуговая сварка металлов (ГМАВ / MIG Overlay)

A semi-automatic or automatic process.

• Uses continuous wire feeding
• Controlled shielding gas environment
• Хорошее качество поверхности

Преимущества:

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

4. Плазменная дуга (ПТА) Сварка

A high-precision overlay method.

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

Преимущества:

• Excellent hardness control
• Прочная металлургическая связь
• Ideal for high-performance wear parts

Key Stages of Weld Overlay Manufacturing

1. Подготовка опорной плиты

• Cleaning oil, ржавчина, и примеси
• Surface grinding or shot blasting
• Ensuring proper welding surface condition

2. Предварительный нагрев (если требуется)

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

3. Наложения сварки

• 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. Послесварочная обработка

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

Формирование износостойкого слоя

Во время сварки, alloying elements such as chromium and carbon form hard carbide structures:

• Cr₇C₃
• Кр₂₃C₆

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

Key Process Control Factors

Фактор	Influence
Heat Input	Controls hardness and dilution
Welding Speed	Affects layer uniformity
Cooling Rate	Determines crack resistance
Сплав состав	Defines wear resistance level
Layer Thickness	Impacts service life

Advantages of Weld Overlay Plate

• Чрезвычайно высокая твердость поверхности (55–65 HRС)
• Strong metallurgical bonding to base plate
• Customizable wear resistance performance
• Длительный срок службы в абразивных средах
• Suitable for large-scale industrial production

Типичные применения

Weld overlay plates are widely used in:

• Горнодобывающее оборудование
• Желоба и бункеры цементного завода
• Системы транспортировки угля
• Системы золы электростанций
• Изнашиваемые детали сталелитейного завода
• Crusher and conveyor systems
• Bulk material transfer equipment