Wear Plates used in mining applications must simultaneously withstand abrasion and resist impact. The materials traditionally used for hardfacing either cannot address both requirements adequately, or are extremely expensive. That’s why more and more manufacturers rely on Metco Joining & Cladding's unique welding hardfacing alloys.
Your Challenge: While current tungsten carbide (WC) solutions meet the requirements for abrasion resistance, they cannot tolerate the extreme impact stress and are very costly. Chromium carbide overlays (CCO), while low in material cost, do not provide adequate abrasion resistance and offers very low impact resistance. Just as important, CCO deposits are not designed to deal with the high dilution rates that occur using the GMAW or BMAW processes. Therefore, up to three layers of CCO, deposited at a thickness of 5 to 7 mm (0.20 to 0.28 in) per layer, are needed to achieve the best performance that CCO can offer — which does not fully satisfy the performance requirements.
Therefore, manufacturers today mostly rely on quench and tempered wear plates. Although inexpensive, these provide good impact resistance, but only minimal abrasion resistance. To achieve the desired abrasion resistance, the plate has to be extremely thick, which reduces equipment performance as a result of the increased weight. In turn, this results not only in higher fuel consumption, but also increases wear on operational components and reduces service life.
Our Solution: In comparison, Metco Joining & Cladding materials, deposited using the same processes, need only one layer deposited at 5 to 10 mm (0.20 to 0.40 in) thick to provide a hardface overlay that meets the needs for both abrasion and impact resistance.
Our innovative materials provide value by saving time in processing, combined with the reduction in material needed to achieve a superior overlay, making it a far more cost-effective solution than either WC or CCO overlays.
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Key GMAW / Open Arc Welding Materials
Key GMAW / Open Arc Welding Materials
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Key PTA & Laser Cladding Materials
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* Cannot be applied via open arc welding
Dipper shovel coated with Metco 8226 after 1700 hours in service exhibits low abrasive wear and no impact damage
Our new computationally developed ferrous-based welding alloys perform better than complex chrome carbides and similar to tungsten carbide-based materials, while providing unparalleled impact resistance.
A further advantage is that they meet their design performance properties after application of the first welded layer — a substantial advantage over other welding materials that require up to three layers to meet the designed performance, which can sum up to considerably increased weight and costs.
An 8 mm (0.3 in) thick deposit of Metco 8224 on a 12 mm (0.47 in) thick wear plate lasted more than 4500 hours and processed 9.5 million metric tons (10.5 million U.S. tons) of ore.
While a 17 mm (0.67 in) thick deposit of CCO only lasted less than 1400 hours and processed 3.5 million metric tons (3.9 million U.S. tons) of ore. This equates to 6 times more ore processed per mm of hardfacing applied.
Materials E-Guide
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