The world’s most wear-resistant fused Alloy Steel Plate

Arcoplate is a wear-resistant fused alloy steel plate manufactured by Alloy Steel International. It is a smooth, chromium carbide rich overlay plate manufactured by a patented production process maximising abrasion resistance and reducing hang up. Arcoplate was developed as an alternative to unpredictable wear rates and high friction characteristics, associated with both – quenched and tempered steel plate and the old technology often used to manufacture traditional bulk weld overlay plates.

Associated costs with unscheduled maintenance or repair are obvious, but more importantly, hidden costs relating to plant and capital productivity losses need to be eliminated wherever possible. Inappropriate wear liner packages significantly affect fixed plant and mobile equipment in a number of ways, these include: hang up of product, spillages around the plant, increased energy consumption, increased friction causing premature wear.

Alloy Steel International’s engineering and design service enable Arcoplate to be supplied as complete wear and anti hang up kit, designed to suit a specific application. Arcoplate can be supplied with stud bolts, countersunk inserts and can be pressed to shape. Arcoplate kits greatly reduce installation time and ongoing maintenance costs.

The team at Alloy Steel understands that different wear factors call for different product options. Arcoplate is offered in different grades, thicknesses, and finishes. With the almost endless combination of product options, there is an Arcoplate solution to suit your wear or hang-up needs.

ARCOPLATE VARIANTS AND SPECIFICATIONS

ARCOPLATE THICKNESSES

Arcoplate consists of a dense, chromium-carbide rich alloy overlay that is fused onto a mild steel base plate. Arcoplate is offered in a range of thicknesses to meet various material handling applications. The range starts with the 4/7 (4 mm alloy on 7 mm base plate) for applications where liner weight reduction is important. The long-wearing 40/20 (40 mm alloy on 20 mm base plate) completes the range and is a popular choice among operations where material wear is at its greatest. Whatever your needs, there is a thickness option to suit. Other thicknesses available on request Arcoplate Stock Sheet™: 1270 mm x 3080 mm Arcoplate Broad Sheet™: from 1900 mm x 3080 mm.

Custom thicknesses can be made from a combination of backing plate options within the range of 6 mm – 25 mm and fused overlay within the range of 4 mm – 40 mm. Our manufacturing maximum total thickness is 60 mm.

Typically fixed plant equipment consists of chutes, transfers, feed bins, fan boxes, fan blades, crushers, screen plates, cyclones, and pipe spools. Fixed plant applications are designed and engineered to maximise the mineral process handling and production. Fixed plant applications face many issues in abrasion and impact wear. Hang up can also contribute to high maintenance and downtime.

Arcoplate is commonly used in fixed plant applications and available in mill finish and the polished surface finishes. In service polished Arcoplate has 39% less coefficient of friction than utility stainless steel making Arcoplate the industry leader for hang up a reduction in chutes, conveyor systems hoppers, and feed bins.

Laboratory tests and field monitoring have proven that Arcoplate outperforms Q&T plate by a factor greater than 8 times and up to double the life of the conventional welded plate. Arcoplate delivers a measurable cost per tonne benefit by the reduction of the plate, maintenance, and mechanical breakdown costs.

Arcoplate mobile plant applications are in high demand in mining. Arcoplate offers premium protection against abrasion, impact, and carryback material. Arcoplate liners are available in ready to fit kit form and can be formed and cut to the specific needs of the application.

Arcoplate packages reduce maintenance costs, contributing to less downtime, and increased production. Typical mobile plant Arcoplate Kits consist of Dozers, Trucks, Excavators, Shovels, Loader Buckets, Graders. Arcoplate is the most desirable product in mobile plant applications where high abrasion and/or hang up issues occur.

The Arcoplate polished plate has 39% less coefficient of friction than utility stainless steel. The standard Arcoplate anti hang up kit can save up to 30% in tipping time with less than 1% of carry back. Laboratory tests and field monitoring have proven that Arcoplate outperforms Q&T plate by a factor greater than 8 times and up to double the life of the conventional welded plate.

Arcoplate delivers a measurable cost per tone benefit by the reduction of the plate, maintenance, and mechanical breakdown costs.

Figure 1. Microstructure of ARCOPLATE 1600

  • ARCOPLATE 1600 is composed of hard and refined chromium-rich primary carbides in a ledeburite eutectic matrix, which complies with the AS/NZS 2576.
  • ARCOPLATE 1600 comprises of > 37 % volume fraction of carbides.
  • Because of single pass hardfacing manufacturing, ARCOPLATE 1600 displays more refined carbides (Figure 1) throughout the plate thickness than conventional multi-layer chromium carbide overlays. Moreover, single pass hardfacing manufacturing offers minimal number of non-metallic and gas inclusions throughout the plate thickness.
  • The presence of hard chromium-rich carbides in microstructure helps in enhancing abrasion resistance, whereas soft ledeburite eutectic matrix helps in enhancing impact resistance by increasing toughness of the plate. This feature makes ARCOPLATE 1600 suitable for both sliding abrasion and impact applications.
  • ARCOPLATE 1600 exhibits excellent bonding with minimal dilution (Figure 2) between weld overlay and base plate, which hinders the shearing failure of the overlay plate during service.
  • Apart from superior microstructure features, ARCOPLATE 1600 comes with smooth top surface, which is difficult to achieve in weld overlay plates manufactured by conventional multi-layer hardfacing techniques.
  • Relief cracks in Arcoplate 1600 do not propagate to the base plate (Figure 3).

Figure 2. Demonstration of excellent fuse line bonding between weld overlay and base plate in ARCOPLATE 1600.

Figure 3. Microstructure of ARCOPLATE 1600 showing a hinderance of crack propagation at fuse line of ARCOPLATE 1600.

Figure 4. Microstructure of conventional multi-layer CCO with inclusions and crack propagation
through layers.

  • Research studies show that crack propagation through layers in hardfacing overlays is a serious issue, which leads to early failure of overlay during service, which is usually found in conventional multi-layer hardfacing manufacturing.
  • The chances of non-metallic and gas inclusions remain high in multi-layer conventional chromium carbide overlay because of more than one layer in weld overlay plate (Figure 4).

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