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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 Oerlikon Metco’s unique welding hardfacing alloys.

Heavy-Duty Ready with the First Layer

Oerlikon Metco’s newly developed materials are designed to solve the challenges faced by wear plate and mining equipment manufacturers, and companies serving this demanding sector.

Innovative Materials that Provide Value by Saving Time

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, does 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 their service life.

Our Solution: In comparison, Oerlikon Metco’s 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.

Oerlikon Metco’s 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.

Key GMAW Materials

  • Metco 8250
  • Metco 8233
  • Metco 8226
  • Metco 8224
  • Metco 8248

Key PTA Laser Materials

  • Metco 1040A
  • Metco 1030A
  • Metco 1051A
  • Metco 51322
  • Metco 51027

New high performance, impact-resistant materials

Oerlikon Metco’s new computationally developed ferrous-based welding alloys perform better than complex chrome carbides and similar to tungste 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.

Case Studies

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.

Metco 8224

  • Fe-based wire deposited via the open arc process that delivers performance approaching that of WC/Ni PTA
  • Lower density than WC/NI PTA requiring less material (in kilos) per plate
  • Can be deposited with a faster, less expensive process (open arc welding)
  • Fe-based and inherently less expensive per pound
  • Can be used with existing CCO hardfacing equipment
  • Drastic improvement in lifetime provides value in a comparison of direct material cost; not including location specific downtime and maintenance costs
  • Increasing Hardfacing thickness, as is commonly done with CCO to provide additional life, is not necessary or recommended with Metco 8224 reducing component weight and reducing direct manufacturing costs

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