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Welding Alloys offers a range of welded overlay plates in both standard and complex carbide models. The welded overlay plates have wear-resistant characteristics that considerably exceed those of tempered and quenched abrasion-resistant steels.

Such exceptional properties are obtained by the formation of very fine and uniformly distributed chromium as well as complex carbides across the thickness of the welded layers.

Advanced equipment and in-house developed technology make sure that Welding Alloys’ products are distinguished by their:

Apart from abrasion resistance, Welding Alloys also supplies materials that are specially developed to resist material loss induced by corrosion, high temperatures, high impact, and also a combination of all these wear mechanisms.

This is a heavy-duty composite overlay wear plate.

Image Credit: Welding Alloys Ltd

This is an ultra-thin welded overlay wear plate that has less than 5 mm overall thickness.

Image Credit: Welding Alloys Ltd

This is an impact-resistant composite overlay wear plate.

Image Credit: Welding Alloys Ltd

Welding Alloys offers overlay products that come in a wide range of thicknesses and are well-suited for all application requirements. Tuffplate™, Hardlite™, and Hardplate™ are offered in both standard dimensions and cut-to-size configurations.

Welding Alloys also provides design and fabrication services across its international network of Integra workshops. In addition, technical and application data sheets are also provided on request.

Table 1. Source: Welding Alloys Ltd

Hardness values are obtained from three-layer deposits

Table 2. Standard dimensions. Source: Welding Alloys Ltd

Other dimensions are available on request

Table 3. Standard thickness. Source: Welding Alloys Ltd

Other thicknesses are available on request

Welding Alloys Group understands that each requirement is unique and that all off-the-shelf products are not suited to meet its customers’ requirements, all the time. Therefore, the company also provides customized overlay solutions to fulfill specific requirements and conditions. For example, these could be stainless steel overlays on carbon steel, or wear-resistant overlays on stainless steel, heat-resistant steels, or wear-resistant steels.

While developing the composite overlay material at Welding Alloys, great emphasis is placed on the regulation of dilution and cooling rates. High dilution ratios can also have an impact on the final weld chemistry, and while hardness may still be in the satisfactory range, the weld metallurgy will not reflect the same acceptable range. In essence, hardness is not a direct measurement of wear resistance and must only be employed as a guideline when investigating the hardfaced overlay plate.

ASTM G-65 Wear Test (independent laboratory). The graph above reflects results from ASTM G-65 wear testing performed by an independent laboratory. The results compare the wear life of various products tested. As an example, Hardplate™ 100 has outlasted 500 BHN quenched and tempered material by a factor of 4 and Hardplate™ 300, by a factor of 7. Image Credit: Welding Alloys Ltd

Welding Alloys has also designed advanced automated welding equipment with the help of suitable welding processes and specialized welding consumables to make sure that weld metallurgy is at its optimum and dilution is kept to a minimum. This ensures maximum possible carbide levels that are distributed across the whole thickness of the overlay.

Most of the plate products offered by Welding Alloys are created using both stinger and oscillated bead methods. These two welding techniques have been refined to create overlay composition as well as weld metal metallurgy that favors the formation and distribution of carbide across the overlay thickness.

For additional information on plate cutting, forming, processing, welding, fitment options, etc., customers can refer to Welding Alloys’ detailed Workshop and Plate Processing Manual available on request.

All plate products offered by Welding Alloys can be thermally processed using plasma or laser cutting methods and can be joined through welding.

These thermal processes do not have any impact on the wear resistance in the heat-affected zone and effectively remove preferential wear that is often observed in such areas when tempered and quenched materials are employed.

Comparative wear test. Image Credit: Welding Alloys Ltd

All products from Welding Alloys are used across the world in various applications and industries, where material loss is caused by wear. Examples of these sectors are given below:

This information has been sourced, reviewed and adapted from materials provided by Welding Alloys Ltd.

For more information on this source, please visit Welding Alloys Ltd.

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