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In the world of heavy industry—from the abrasive slurry of dredging to the high-heat kilns of cement plants—material failure isn’t just an inconvenience; it’s a massive financial drain. If you are struggling with frequent liner replacements, understanding the metallurgy of Chromium Carbide Overlay (CCO) is your first step toward 5x longer service life.
When is CCO Plate the Right Choice?
Not all wear is the same. CCO is specifically engineered for environments where sliding abrasion is the primary enemy.
Best-Fit Scenarios:
- Fine Particle Erosion: Handling sand, gravel, or slurry with high quartz content.
- Brittle Impact: Processing limestone, coal, or sandstone where the material crushes easily.
- High-Heat Environments: Standard steel softens; our Complex Carbide range maintains its “bite” up to 600°C (1100°F).
Chromium vs. Complex Carbides: What’s the Difference?
At Welding Solution, we provide two distinct levels of protection depending on your operational stress:
| Feature | Standard CCO Plate | Complex Carbide Plate |
| Alloys | Chromium-rich | Cr + Niobium (Nb), Molybdenum (Mo), Vanadium (V) |
| Hardness | 58 – 62 HRC | 62 – 66 HRC |
| Max Temp | ~350°C | Up to 600°C |
| Best For | General mining & cement chutes | Extreme heat & ultra-fine erosion |
Chromium or complex carbides are dispersed in a steel matrix.
Fine-grained borocarbides makes the overlay material more resistant to heat and impact.
The Science of the “Staggered Cracking Pattern”
A common question we receive at info@weldingsolution.pk is: “Why does my new plate have tiny cracks on the surface?”
The answer: These cracks are a sign of quality. Known as “stress-relief cracks” or a staggered cracking pattern, they occur naturally as the hardfacing layer cools on the mild steel base plate.
- Why they matter: These cracks allow the plate to be rolled and formed into cones or pipes without the overlay delaminating from the base.
- Performance: They do not reduce wear resistance; they ensure the plate remains flexible enough for custom fabrication.
Welding beads showing the perpendicular staggered cracking pattern.
Fabrication: Beyond the Flat Plate
Welding Solution doesn’t just ship raw materials. We provide ready-to-install wear parts:
- Custom Bending: We roll CCO plates for fan housings and pipe liners.
- Precision Welding: Our beads are deposited in a dense steel matrix to ensure no “soft spots” exist.
- Hardfacing Repairs: Using specialized welding wires and stick electrodes, we can rebuild your existing equipment on-site.
Overlay wear parts created by manually welding a hardfacing layer on a steel base with welding wire or stick electrodes.
The base plate is covered with welding beads of hardfacing material that is deposited in one, two or sometimes even three layers.
Frequently Asked Questions (FAQs)
What is the typical lifespan of a CCO plate?
In sliding abrasion applications, a CCO plate typically lasts 3 to 5 times longer than AR400 (Hardox) and up to 10 times longer than mild steel.
Can I weld CCO plates to my existing machinery?
Yes. The base plate is usually made of weldable mild steel. You can use standard E7018 electrodes to weld the “back” of the plate to your structure.
Does Welding Solution offer custom sizes?
Absolutely. We offer standard sheets (e.g., 1500x3000mm) but can plasma-cut any geometry based on your engineering drawings.
Get a Technical Consultation
Stop replacing parts every few months. Let our engineers analyze your wear patterns and suggest the right carbide matrix for your budget.
- Email: info@weldingsolution.pk
- Website: www.weldingsolution.pk
- Location: Lahore, Pakistan (Serving nationwide)
