Frequently asked questions: Wear Plates
What are Wear Plates?
Wear plates comprise a base plate of construction steel hardfaced with a selection of chromium and complex carbide-based cored welding consumables. Wear Plates take the brunt of wear phenomena such as abrasion, impact, corrosion and erosion, extending the life of your machinery and keeping it running smoothly. Wear Plates rely on their chemical and mechanical properties, such as alloying elements, hardness and metallurgical structure to resist wear. Think of them as the ironclad armour for your industrial applications.
What are the Types of Wear Plates?
Wear Plates are available on the global market in various types, shapes and sizes, ranging from quenched and tempered materials to composite welded overlay products making use of chromium carbide and complex carbide alloys, for a diverse range of applications – there’s a wear plate for every wear type your equipment faces. Besides metallic wear plates, materials such as ceramics (alumina, zirconia, Basalt, etc.), polymers, and even paints and thermal sprayed coatings are also available to resist wear. Contact a specialist to learn more about the wear plate solutions available to suit your needs.
How to Choose the Right Wear Plate?
Selecting the perfect wear plate isn’t just about hardness. Wear phenomena play a crucial role – are you dealing with fine, high-speed particles, large pieces of rock or ore, corrosive fluids or high temperatures? Define your specific needs in terms of wear life, liner package weight, manufacturing capabilities (bending, rolling, welding…), ease of installation etc. Explore the material options, consult our wear plate pages for guidance, and remember, that budget and maintenance requirements play an important role. The correct option should have benefits that outperform the current option and reduce your Total Cost of Ownership. Contact one of our technical experts for more information on choosing the right wear plate.
How to maintain your wear plates?
Regular wear plate inspections ensure they remain functional for longer periods. Measuring wear will provide valuable information to select optimised products, thickness and dimensions. Knowing when to retire a worn-out liner can prevent unplanned maintenance and unexpected repair costs to the structural parts of your equipment. Loose or damaged liners should be replaced or repaired. Proper care can prolong lifespan and keep your equipment running for extended periods.
If you are looking to improve the lifespan of your wear plates, please contact us to request a wear audit.
What is the manufacturing process of wear plates?
Quenched and Tempered wear plates start as alloyed liquid metal which are cast into strips, rolled down to thickness and heat treated to the required hardness.
Chromium and Complex Carbide overlay wear plates make use of a construction steel base material, onto which an alloy is applied using automated arc welding. Upon solidification of the weld metal, the intended abrasion resistant properties are achieved. These are in the form of extremely hard and resilient carbide particles, evenly distributed throughout the thickness of the weld metal.
What are the benefits of wear plates?
Wear plates don’t just protect your equipment; they enhance its overall performance. Longer wear life means less downtime, fewer replacements, fewer stoppages and higher productivity and production throughput. Reduced maintenance saves you resources, improves efficiency and keeps your operation running smoothly, while enhanced safety protects both your equipment and your workforce. Using the correct wear plates presents significant cost-saving opportunities for the industry. Choose the correct wear plate by speaking to an expert.
What type of applications can wear plates be used for?
From mines to construction sites, from factories to hydropower plants, wear plates are ubiquitous. Mining equipment, loader buckets, crusher jaws, paper manufacturing, and sugar mills – just a few places where these silent guardians protect against wear and tear.
Can complete components be fabricated from wear plates?
Absolutely! In areas like chutes and hoppers, where ultimate wear resistance is key, entire components can be crafted from wear plates, becoming unyielding bastions against the most punishing environments.
Wear plates are hard, brittle and resilient to deformation, how can they be rolled or formed?
Being a metal, even these materials exhibit a level of formability. Quenched and tempered materials can be rolled, bent, formed, drilled and welded, but the necessary care and specific knowledge in working with these materials are required.
Welded overlay materials have the advantage of the softer, more ductile construction steel backing material, making them surprisingly flexible, and within limits. They too can be rolled, formed and welded, but they require a specific knowledge of their properties to do so successfully. Chromium carbide-based wear plates for example cannot be drilled, but the use of inserts makes fixing using bolts possible.
What are the Materials used in producing overlay Wear Plates?
Alloys of Iron, Carbon and Chromium form the backbone of almost all overlay wear plates, with their strength bolstered by chromium and complex carbides. Quenched and Tempered wear plates tap their wear resistance from a fine balance between small additions of alloying elements combined with the heat treatment they receive. The choice and type of material depend on the type of wear you’re facing – choose the correct wear plate by speaking to an expert.
What are the Quality Factors of Wear Plates?
The basic metallurgy and inherent hardness of the materials are just one piece of the puzzle. Precise manufacturing techniques ensure consistency, uniform carbide distribution and through-thickness properties. Rigorous testing throughout the production process guarantees every plate is a true champion.
How to Choose a Wear Plate Supplier?
Look for experience and expertise, a diverse range of high-quality, certified products, and the ability to customise products to your specific needs. Consider how the supplier is addressing the problem to reduce the Total Cost of Ownership, and if they are just supplying something off a shelf, or if they are prepared to assess, advise, design and manufacture the best possible solution. Pricing and customer service are important too, and don’t forget to consider factors like delivery times and their commitment to sustainability.
For more information, please contact us to speak to one of our technical experts.
Which type of wear plate is best for heavy industrial equipment?
Chromium and complex carbide-based alloys offer the best combination of abrasion, erosion and impact resistance. Industries such as mining, cement, material handling etc, rely on wear plates that can withstand extremely demanding environments, such as handling rocks, minerals, and heavy loads. With this said, wear protection is not a one-size-fits-all scenario, and depending on the wear phenomenon, the customer requirements in terms of wear life, weight restrictions, ease of access etc, a combination of various types of wear plates in the same application could be the ideal solution.
Can wear plates be used in food processing applications?
Absolutely! However, there are requirements to use approved food-grade materials such as stainless steel or high-performance polymers. Opt for plates with smooth surfaces and easy-to-clean designs, such as our Hardplate™ FlowMax.
Are there wear plates designed specifically for corrosive environments?
Yes! When it comes to welded overlay materials, various alloys exist and various low-dilution welding processes are in use to ensure the production of corrosion-resistant wear plates to be successfully used in various environments, such as water, acids, alkalines, gases, slurries etc. Our Hardplate™ solution is designed to withstand harsh and corrosive environments.
What type of wear plate is best for high-impact applications?
The typical solution to impact is to go thicker, but with a material change, the opposite could be true. When using Titanium Carbide-based material, the thickness of liners in impact areas can often be reduced, compared to quenched and tempered materials. Another advantage of Titanium Carbide is that besides excellent impact resistance, it also provides excellent resistance against abrasion, making it suitable for various applications. Our Tuffplate™ solution is one of our premium welded, composite overlay products, ideal for a combination of abrasion, pressure, and impact.
How often should I inspect my wear plates?
Regular inspections are key. Monthly checks are recommended, especially in high-wear environments. Focus on the high-wear areas. It is also good practice to inspect every time the equipment is down for maintenance. Contact one of our technical experts for more information.
What are the signs that a wear plate needs to be replaced?
Excessive wear, visible cracks and tears, deformations like bending or warping, and reduced performance (e.g., increased noise or vibration) are all indicators that replacement is needed. When using welded overlay materials, the liner needs to be replaced once the overlay portion is worn away. At this point, all that is left is the construction steel backing, which does not provide any resistance against wear. If you are looking to improve the lifespan of your wear plates, please contact us to request a wear audit.
Why do some welded overlay Wear Plates have cracks on the surface?
The carbide-based family of welded overlay materials typically exhibit cracks on the surface. These are called stress relief cracks and are formed upon cooling of the weld metal. The majority of them run perpendicular across the weld beads. The reason for these cracks is attributed to the stress of the solidified contracting weld metal exceeding the strength of the material. These cracks are normal and inherent to the carbide-based family of welded overlay materials and do not negatively affect the quality of the plates. They also do not propagate beyond the fusion line. Welded overlay wear plates are designed to have optimum wear resistant properties, and not the strength of the material.
Can I repair damaged wear plates?
Minor damage like small localised areas of high wear can sometimes be repaired through manual hardfacing, but distortion of the plate, weld time, access and cost of the repair need to be kept in mind. However, major cracks or significant wear generally require full plate replacement. Consult a qualified technician for proper assessment.
How can I get the most life out of my wear plates?
The first line of defence is installing the correct line material and thickness. In addition, regular inspection, proper installation (ensure appropriate fastening and alignment) and avoiding overloading the equipment are crucial. Implementing a preventative maintenance schedule to address wear before it becomes critical extends wear life significantly.
What are some common mistakes people make when using wear plates?
Overlooking maintenance, selecting the wrong material for a specific application, improper installation leading to misalignment or stress points, and overloading equipment beyond the wear plate’s capability are common pitfalls. Consulting specialists help avoid these costly mistakes. Another common mistake is to use materials based on their individual cost, as opposed to the Total Cost of Ownership of the total package. Although the initial cost is less, using a $1,000.00 liner, lasting 2 months is more expensive than a $3,000.00 liner, lasting 7 months.
What are the specific regulations for wear plates in the construction industry?
Regulations and certifications vary by region and country. Always consult local codes and authorities for specific requirements.
Are there any certification requirements for wear plates used in oil and gas applications?
Wear plates in oil and gas environments should meet relevant standards for safety and reliability, ensuring suitability for hazardous environments. However, regulations and certifications may vary by country and specific application. Always consult local codes and authorities for specific requirements.
What are the safety considerations when working with wear plates?
Always wear appropriate personal protective equipment (PPE) such as gloves, safety glasses, and sturdy footwear. Utilise lifting equipment for heavy plates and follow safe handling procedures to avoid injuries. Proper training and awareness are crucial for safe operation. It is also important to realise that plate grabs, designed for softer materials such as construction steel, may now grip hard, wear resistant material with the same effectiveness. Magnetic devices may not also work as effectively on certain wear resistant materials.