In the relentless quest for materials that can withstand the extreme conditions of industrial operations, high impact chromium carbide (HIC) plates have emerged as a superhero in the field of wear resistance. With applications ranging from mining to cement manufacturing, understanding the nuances of HIC plates can be pivotal to the efficiency and longevity of equipment. In this comprehensive guide, we will take a deep dive into the world of HIC plates&#;what they are, how they are made, and why they matter.
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HIC plates, also known as chromium carbide overlay (CCO) plates, are incredibly hard plates that are welded onto metal substrates to protect surfaces from abrasive wear. Think of them as an ultra-tough outer armor that extends the life of machinery and equipment. The term &#;high impact&#; refers to a key enhancement&#;HIC plates are specifically designed to not only handle abrasion but also resist impact, providing a comprehensive defense for vulnerable surfaces.
The secret to the extraordinary resilience of HIC plates lies in their composition. Typically, these plates are made of a mild steel base that is coated with a layer of complex carbides. Chromium is the primary alloying element in these carbides, providing superior hardness and wear resistance.
The fabrication of HIC plates is a meticulous process. Below is an overview of the key steps involved.
The application of HIC plates offers a myriad of advantages, making them the go-to choice for industries that demand high durability and performance.
HIC plates significantly increase the lifespan of equipment by providing a harder, more durable surface that is virtually impervious to abrasion. This translates to reduced maintenance, downtime, and replacement costs.
Unlike many traditional wear-resistant materials, HIC plates are designed to withstand not only abrasion but also heavy impacts. This provides a dual-layer of protection, ensuring that the integrity of the underlying structure is safeguarded against all forms of wear and tear.
With machinery operating at peak performance for longer periods, productivity is naturally enhanced. HIC plates allow for a more efficient and consistent output without the need for frequent interruptions for repairs or maintenance.
HIC plates can be custom-tailored to fit almost any size or shape, adapting to a vast array of applications. Whether it&#;s the bucket of an excavator or the lining of a chutework, these plates can be designed to precise specifications.
Industries that involve bulk material handling, such as mining, power, and construction, can reap substantial benefits from the implementation of HIC plates. When choosing the right type of HIC plate, several factors come into play.
Understanding the nature of the wear that your equipment is subjected to is fundamental. This includes analyzing the types of materials, the angles and patterns of abrasion, and the expected life cycle of the equipment.
A one-size-fits-all approach does not work with HIC plates. The plate&#;s thickness, carbide composition, and welding technique must be selected based on the unique challenges of your application.
While the initial investment in HIC plates may be higher than other wear solutions, a comprehensive cost analysis will often reveal significant long-term savings. Consider the cost of downtime, labor, and replacement parts over the lifespan of your equipment.
Proper installation and maintenance are critical to the effectiveness of HIC plates. Here&#;s how to ensure they perform optimally.
HIC plates should be installed by trained professionals who understand the nuances of welding and working with these specialized materials. The welding process, temperature control, and the quality of the weld itself are all crucial factors.
Regular inspections should be conducted to monitor the condition of the plates. Any signs of cracking, peeling, or wear on the overlay should be addressed promptly.
In the event that maintenance or replacement is necessary, it is important to use the correct procedures to preserve the integrity of the entire system. This may involve reclamation of the original substrate and reapplication of the HIC plates.
The field of wear protection is continually evolving, and the future of HIC plates is no exception. Innovations in material science and fabrication techniques are likely to lead to even more durable and efficient versions of these plates.
Research is ongoing to develop new materials that offer superior wear and impact resistance. These materials may include different combinations of carbides, as well as alternative base metals.
Advances in welding technology and the application of overlay techniques might result in HIC plates that are easier to produce, yet even more robust.
Integration of digital sensors and monitoring systems could allow for more proactive maintenance, with early warnings of plate degradation and wear, enabling timely corrective actions.
High impact chromium carbide (HIC) plates represent a significant leap forward in the realm of wear protection. From their remarkable hardness to their diverse applications and impressive durability, HIC plates are redefining the standards for longevity in industrial equipment. By understanding their composition, benefits, and correct usage, industries can leverage the power of HIC plates to ensure their operations remain at the cutting edge of efficiency and performance.
Implementing HIC plates is not just about mitigating wear&#;it&#;s about investing in the future of industrial sustainability. If you&#;re looking to fortify your equipment against the rigors of daily operation, it may be time to consider the impact of HIC plates on your bottom line. With the right approach to selection, installation, and maintenance, these plates could be the armor your machinery needs to not just survive, but thrive.
Chromium carbide wear overlay plate means that the high hardness self-protecting alloy wire is uniformly welded to the substrate by special equipment and automatic welding process on the ordinary steel plate (substrate), and the number of compound layers is one to two layers to multiple layers.
Chromium carbide plate has been initially popularized and applied.
Some blast furnace water flushing slag pipes and slag ponds of iron smelters are made of chromium carbide plates, which have been used for more than two years without damage.
On the cement production equipment manufactured by cement machinery factory, chromium carbide plate is used as lining plate, and the effect is very good, and its product quality has increased the competitiveness.
The gas plant uses chromium carbide plate to manufacture coke hopper, the service life of steel plate hopper is only one month, the service life of chromium carbide plate hopper is more than two years.
Due to the good performance of chromium carbide plate, it is widely used. However, it is also seen that some enterprise purchasing personnel are not clear how to distinguish the good and bad quality of overlay wear plate.
Then how to quickly judge the quality of the overlay wear plate? It needs to be judged from the following points.
The first thing to look at is whether the size of the whole plate meets the specifications. Generally, the plate number, plate size and welding specification will be clearly and accurately marked on the surface of the product.
Secondly, see whether the size of the weld channel is uniform. The width of the weld channel is uneven, the error is more than 5mm generally unqualified products, except for the last weld channel of the welding gun.
In addition, welding specifications, must meet the requirements, otherwise it is unqualified products.
Different specifications of the surfacing wear plate have different thickness standards, measuring the middle of the weld channel, measuring five values to take the average. Average thickness tolerance 0 to 0.7mm is the most perfect, thickness tolerance >1mm is generally unqualified products.
Surface forming to pay attention to the details of more.
The first observation of whether there are pits (diameter greater than 4mm, depth greater than 2mm dents defined as pits), whether the pit repair. General repair traces, a single pit repair area is best within 20mm * 20mm.
The second to see the weld channel surface to pay attention to whether there is a porosity (wear-resistant layer within the cavity due to poor gas overflow is not filled by the laying molten metal. The weld channel is not well formed (caused by low current or welding wire), arc break and other problems.
Thirdly, we should observe the combination of substrate and wear-resistant layer. Wear-resistant plate large area off, wear-resistant layer and the combination of the substrate a large area of porosity, after welding caused by cracks in the substrate, welding leakage and other problems are generally substandard products.
Through naked eye observation and calipers and other tools, we can roughly judge the quality of wear-resistant plate.
The chemistry will be different for different applications and specifications as well as for each company&#;s R&D capability and production process. The hardness (HRC) of conventional wear plates should not be less than 55.
The main thing is to know what styles of surfacing wear plates are available on the market, the performance and price of different styles, to provide a basis for purchase.
Nowadays, there are more manufacturers that provide custom-made surfacing wear plates, and the comprehensive strength of different manufacturers is not the same, which makes the performance of the products different.
At present, there are many kinds of purchase channels, such as contacting manufacturers to customize, to the wholesale market to buy. Before choosing the purchase channel, understand the purchase price of each channel, for the same, the same kind of surfacing wear plate, try to choose the purchase channel with lower offer.
Of course, there are many other issues to consider when buying surfacing wear plates, such as paying attention to the quality of the surfacing wear plates. If the quality does not go up, it will certainly affect the service life and use effect. Surfacing wear plates are formed after adding special elements to ordinary steel, such as Si, Mn elements, etc., which can enhance the wear resistance of steel plates. Before purchasing, customers who are in a position to do so can also go on a field trip to the surfacing wear plate manufacturer to understand the manufacturer&#;s production capacity, scale of operation and industry fame.
When dealing with CCO wear plates, the wide majority of people think that the more layers a particular wear plate has, the better.
A multi-layered chromium carbide wear plate for strength and durability purposesSince their main purpose is to absorb friction and abrasion, not letting it reach the part itself, you&#;d think the same, right?
However, that is not true. Having more does not always translate to good or better.
Even if there&#;s just one pass or one layer of chromium carbide wear plate, if it has been welded properly and appropriately, and if the chemistry of the elements and compounds are compatible with one another, it&#;ll be better than a normal and a regular CCO wear plate that has a double pass.
Many industries and business areas feel the need to use chromium carbide overlay wear plates.
The Pulp and Paper industry &#; one of the industries that use CCO wear platesThe most common industries that are vocal about their need to use CCO wear plates include the construction or the structural industry, and the heavy earth moving industry.
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To cite other industries that need it, they are:
The gas & oil industry use wear plates for many different parts and components, including valves, boilers, heat exchangers, compressors, chutes, conveyors, and many more.
For the pulp and paper industry, wear plates are regularly applied and integrated to refiners, pulpers, chippers, cyclone fans, mixing machines, pipelines, etc.
With the mining and/or coal mining industry exposed to frequent abrasion and friction, the use of wear plates has been seen as a standard in many different situations.
As a matter of fact, the most common machines/equipment that are installed CCO wear plates on include dumpers, bulldozers, graders, excavators, rotary blades, loaders, and many more!
Apart from those industries, there are other industries that rely on chromium carbide overlay wear plates for the life and the prolonging of their parts/machines.
The quick and easy answer to that is no &#; wear plates, especially chromium carbide overlay plates wouldn&#;t have too much of a difference if it has solid paint or not &#; or if the paint is cranked and mixed up.
This probably is the most common misconception that experienced and seasoned workers have when choosing CCO wear plates.
Color shall never be a side of judgment in choosing which CCO plates to buy. As a matter of fact, you might even see hairline cracks, check-cracks, and other thin lines on the CCO plate when you first purchase it.
To be fair, they&#;re completely normal! Seeing a thin-line crack isn&#;t a sign that the CCO plate has been damaged or worn-out; it is, in fact, a natural stress relieving effect that the plates have.
There are a couple of things you should look for before you purchase chromium carbide overlay wear plate.
WALDUN&#;s chromium carbide wear plates stacked and lined with one anotherAs mentioned above, the thickness or the number of passes isn&#;t significant enough if the chemistry is not thought of fully.
That being said, here are the best tips so you&#;ll be able to purchase the best and the highest quality of CCO wear plates.
While pass thickness isn&#;t much of a big deal, the larger the size of the CCO plate, the better.
Imagine a wear plate that&#;s smaller than the bucket you&#;re trying to cover. Also, if you are going to install it on a loader or an excavator, would a small one fit it? Probably not!
There are manufacturers that produce large-sizes chromium carbide overlay wear plates, while those that just weld two (2) or more small pieces together. You need to make sure that you&#;re purchasing large and wide-sized CCO wear plates for better results.
So, checking on the history, the background, and the overall capability of the manufacturer is important. We&#;ll get to that in a later part of this guide.
Most, if not all CCO wear plate manufacturers offer free samples to clients and businesses. These samples are ways to check if the product or the CCO wear plate is fit to the need of the client.
Should they provide a sample, you can do and perform tests and assessments to that particular sample.
But, there are a few chromium carbide wear plate suppliers that do not offer samples; it&#;ll be better to work with a manufacturer that provides free samples.
Different chromium carbide overlay wear plates have different hardness levels. The hardness would depend on a wide range of factors, such as the heat treatment, the material used, and many more.
On average, the hardness levels of chromium carbide overlay or CCO wear plates are usually around 59 to 64 HRC.
But, the harder the wear plate is, the more brittle and fragile they are. High-level hardness CCO wear plates are prone to cracking, breaking, and splitting.
To add extra information and knowledge to this, here&#;s how hardness is measured.
Measuring the hardness of a particular item can be done in many different ways. However, the most common ones are the Brinell and the Rockwell scale.
Typically, measuring the hardness of CCO wear plates is done via the Rockwell (HRC) or the Hardness Rockwell C.
59 HRC, when converted to Brinell, is 590 HB. 64 HRC, on the other hand, is measured ad 668 HB.
The higher the number, the harder the particular item or CCO wear plate is. So, it might seem typical to see the regular or the average hardness level of chromium carbide overlay wear plate is at 59 to 64 HRC.
However, different manufacturers, use different materials and products to produce and to manufacture CCO wear plates &#; they&#;re not all the same.
There are manufacturers that produce malleable CCO wear plates, while there are those that manufacture CCO wear plates that have HRC levels over 72.
This property measures the capacity of the CCO wear plate to be worked on under temperatures.
If we put it in average, the maximum service temperature of these plates is at 600 to 650 degrees Celsius or 1,100 to 1,200.
When it comes to the impact, this is the capability of a CCO wear plate to be able to resist and absorb impact.
The amount of abrasion resistance of a particular chromium carbide overlay plate depends on the composition of it.
Abrasion refers to the wearing out of the surface such as scratching, rubbing, and marring.
Lastly, the service life or the lifespan of the CCO wear plate is relevant and significant as well.
Although the life expectancy would still depend on usage, as well as other external influences, manufacturers give the expected service life of their CCO wear plates for clients to have a general threshold of until when they&#;re effective.
While these things are a lot to digest, the best thing to do is to still look into the legitimacy and the experience of the manufacturer you&#;ll be working with.
The quality and the overall effectiveness of chromium carbide wear plates will, of course, depend on the one who made it.
If the chromium carbide wear plate manufacturer isn&#;t reputable or if they&#;re known to provide CCO wear plates that are not-up-to-standard, then you should already think twice about working with them.
To illustrate further, there are newer manufacturers of wear plates that skip heat treatment because they think it&#;s not a collaborative factor in the strength and quality of the material. These manufacturers are obviously inexperienced and are not used to other procedures in which wear plates are used for.
To successfully check the background or the history of a manufacturer, you can try the following:
While the reviews you see online aren&#;t much impacting, the reviews that real clients they had could be everything you need to decide.
If you see a line of reviews that is 100% positive &#; then, the chances of that manufacturer being world-class is higher, you can immediately come up with a conclusion that they&#;re easy-to-work-with.
Another thing you can do is to find previous clients of that particular manufacturer. Try communicating with those clients and ask about the service and the products the manufacturer is offering.
Were they up to the expectations of the client? Or were there a lot of challenges towards completion?
Lastly, the condition or the ambience of the manufacturing plant reflects directly on the quality of service the manufacturer has.
The plant or workspace reflects the quality of products and servicesSince the rise of technology, many suppliers opened a virtual setting of their manufacturing plants and offices.
This paved way for clients to be able to &#;visit&#; their factories without being physically there. Oftentimes, the best manufacturers would offer a virtual tour of their factory.
They wouldn&#;t be shy to let their factories and their manufacturing processes out.