Hardfacing (also known as wear-resistant overlaying, hard surfacing, weld overlaying, or cladding) is a specialized welding process that applies a layer of wear-resistant material onto the surface of a base metal. This process enhances the material’s resistance to abrasion, erosion, impact, and thermal wear. Standard hardfacing methods include arc welding, plasma transfer arc (PTA), and thermal spraying, utilizing alloys enriched with carbides, borides, or other durable materials. Hardfacing significantly increases the service life of industrial components, reducing downtime and maintenance costs in high-wear environments. It also promotes cost-effective and sustainable industrial operations.
VORAX Hardfaced Wear Plates are designed to combat wear from abrasive materials such as rocks, ores, clinker, coal, and soil. By extending the lifespan of critical components, VORAX overlay plates lower downtime, minimize maintenance frequency and cut replacement costs, offering an excellent return on investment. VORAX engineers customize the hardfacing material composition to meet specific wear conditions and optimize performance. The total thickness of VORAX hardfaced plates combines the base plate (typically S235 or similar steel) and the wear-resistant overlay layer. We offer chromium carbide hardfaced plates starting from 3 + 3 mm and tungsten carbide PTA hardfaced plates starting from 2 + 1 mm.
Chromium carbide hardfaced plates are advanced wear-resistant products designed to withstand the challenges of abrasion, erosion, and moderate impact in demanding industrial environments. VORAX chromium carbide hardfaced plates offer a cost-effective and reliable solution to reduce wear, enhance equipment durability, and improve operational efficiency in high-demand applications.
These chromium carbide overlay plates consist of a mild steel or alloy steel substrate overlaid with a high-hardness chromium carbide layer. With hardness levels typically ranging from 55 to 65 HRC, depending on the hardfacing thickness and alloy composition, these plates deliver exceptional durability compared to conventional steel or manganese plates. The mild steel base provides structural support and excellent weldability, ensuring seamless integration into various industrial systems. By alloying the hardfaced layer with elements like boron, niobium, molybdenum, and vanadium, VORAX enhances wear resistance by refining the microstructure, increasing toughness, and promoting secondary carbide precipitation. More on hardfacing alloys here. According to ASTM G65 standard, VORAX chromium carbide plates deliver wear resistance up to 20 times greater than standard S235 structural steel, thanks to the dense distribution of hard chromium carbide particles within the overlay.
The hardfacing layer in VORAX plates primarily consists of chromium carbide embedded within a durable metallic matrix. With a typical carbide hardness of 1600-1800 HV, chromium carbide provides high resistance to abrasion and erosion, ensuring reliable performance in high-wear environments. These chromium carbide wear plates are effective at temperatures up to 650°C (1200°F) during continuous use.
Standard VORAX chromium carbide hardfaced plates are available in dimensions of 1500 mm × 3000 mm (5 ft × 10 ft). Custom sizes and shapes can also be manufactured to meet specific application requirements, providing flexibility for various industries. VORAX chromium carbide overlay plates can be cut, formed, or welded, though their hardness necessitates the use of specialized tools and techniques. For precision cutting, plasma or water jet cutting is recommended, as conventional machining tools may wear out quickly against the hard overlay. These plates can be fabricated into complex shapes, such as pipes, cylindrical liners or curved surfaces, making them highly versatile for diverse industrial applications. More about hardfaced pipes, elbows, bends, tees, wyes, and other components here.
VORAX tungsten carbide plasma-transferred arc (PTA) hardfaced wear-resistant plates are premium solutions engineered for extreme durability in the harshest industrial environments. These plates feature a base metal overlaid with a tungsten carbide-rich layer of up to 3000 HV, resulting in exceptional wear resistance. Independent ASTM G65 abrasion testing confirms that VORAX tungsten carbide plates offer wear resistance up to 50 times higher than S235 steel and up to 40 times greater than 400 HB wear-resistant plates, thanks to the superior hardness and toughness of embedded tungsten carbide particles.
VORAX tungsten carbide wear-resistant plates provide unparalleled performance in resisting abrasion, erosion, and impact, making them ideal for demanding industries such as mining, dredging, power generation, and heavy-duty material handling. These plates ensure a long service life and require minimal maintenance, delivering outstanding value for high-wear applications.
Tungsten carbide is one of the hardest and most durable materials available. The PTA (Plasma Transfer Arc) process ensures excellent bonding between the hardfacing layer and the base steel plate, creating a highly wear-resistant surface. The overlay consists of tungsten carbide particles embedded in a robust cobalt or nickel-based matrix, with a tungsten carbide content ranging from 40% to 70%, depending on the application requirements. These plates provide unparalleled resistance to sliding abrasion and particle erosion, making them ideal for extreme wear conditions.
The overlay thickness can be customized to meet specific service life requirements. Standard VORAX tungsten carbide hardfaced plates measure 1000 mm × 1000 mm (3 ft 4 in × 3 ft 4 in), with custom sizes and shapes available to suit specialized applications. VORAX tungsten carbide plates can withstand temperatures up to 800°C (1470°F), making them highly suitable for high-temperature applications such as furnace components and kiln liners. Due to the hardness of tungsten carbide surfaces, traditional machining methods are ineffective. Diamond abrasives are the only viable option for fine finishing. For welding, specialized procedures are used on the base plate to ensure structural integrity and performance.