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Ultra Wear™ Chromium-Carbide Plate

Ultra Wear is a high Chromium Carbide overlay deposited on a high grade mild steel plate. This forms an extremely hard surface that provides exceptional wear-ability and slide-ability. The process is achieved by applying accurately blended metal powders to a mild steel base plate by thermally fusing both with a process called sub-arc welding.

 Fusion takes place under a thick flux cover, thereby eliminating oxide formation and gas pick-up, resulting in an inclusion free deposit. It also produces a relatively even and smooth surface with weld passes approximately 1½” in width covering the base material.

 With all Chromium Carbide Weld deposits, it is common for fine cracks to form across the weld seams. These cracks do not propagate into the base material and will not affect the wear properties of the overlay.

 Ultra Wear can easily be cut to custom sizes by using Plasma Arc. Plates can be welded together using common electrodes to join backing plates which does not affect the wear resisting properties. Ultra Wear can be rolled or formed to custom shapes.

 Metallurgical properties achieved in this accurately controlled process utilizing the proper blend of metal powders results in an overlay with an evenly distributed chromium carbide and extreme hardness. By using small carbides, Ultra Wear obtains a consistent wear on the matrix that hold them in place.

 Since Chromium Carbide overlay has a very low coefficient of friction, when combined with the particularly flat, even finish of Ultra Wear, it is best suited for areas where customers have problems with hold back of their product.

 For a wear overlay plate in the Ultra Wear hardness range, the forming qualities are excellent even at thinner thicknesses with both chrome in or out of a formed radii. This is the natural result of a consistent dilution zone.

Applications

Using Ultra Wear in the following applications will improve productivity, therefore, reducing wear and down time.

Cement Plant	Power Plant	Pulp & Paper
Fan housing Material Separators Buckets Flat Back Elbows Hoppers Scroll Liners Chain Guide Liners Fan Hoods	Hopper Lines Chutes Scroll Liners Fan Housing Classifier Cone Ash Conveyor Chain Guide Line	Transitions Deflector Plates Cyclones Flat Back Elbows Chain Guide Liners Conveyor Trough Bark Shredder Fan Housing Scroll Liner Fan Blades
Asphalt & Construction	Mining	Steel Industry
Fan Housing Liner Fan Blades Screed Plate (Paving Machine) Deck Plate (Paving Machine) Buckets Pug Mills Mould Board Liner Snow Plow Shoes Discharge Chute (Asphalt Driver) Slat Conveyer Line	Dragline Bucket Liner Truck Box Liner Hoppers Chutes Shovel Liner Crusher Wall Liner Breaker Screens Sizing Screens	Hopper Liner Chute Liner Dust Collector Scroll Liner Fan Blade Fan Housing Guide Liners

Processing and Installation

SHAPING CUTTING & FORMING

 Ultra Wear can be easily cut to specifications using Plasma Arc or Arc Air gouging. Although Ultra Wear can be rolled both with and across the weld seams forming or rolling perpendicular to the weld seams produces the most consistent results. Whenever possible, Chromium Carbide overlay should be formed to the inside of the radius, however, it can be formed to the outside of bends.

 When forming Chrome Carbide to the weld seam with the Chrome Carbide to the outside of bends, a greater radius is required. Contact your Wilkinson Steel Ultra Wear representative for more details.

WELDING OF ULTRA WEAR

 When structural strength of the weld is required, the following procedure applies:

Mild Steel Base Material E7018
Fusion Point of Mild Steel & Chrome E309L
Hard Surface Stoody 33 or 35

 When structural strength of the weld is “not” required, the following procedure applies:

 Mild Steel Base Material E7018
Hard Surface Stoody 33 or 35
Wear resisting properties are not affected by welding

 MACHINING

 Ultra Wear cannot be machined or drilled by conventional means. Both countersunk and square holes must be cut by Plasma Arc.

 INSTALLATION

 Weld beads on overlaid plates should be installed at 90 degrees to the flow of material whenever possible, in order to obtain maximum wear life.

 In some cases, to prevent undesirable turbulence, it is necessary that weld beads run in the direction of flow (Fan Blades).

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