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.
Typical 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 down time.
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 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 conventional welded plate. Arcoplate delivers a measurable cost per tonne benefit by the reduction of plate, maintenance and mechanical breakdown costs.
Arcoplate mobile plant applications are in high demand in mining. Arcoplate offers premium protection against abrasion, impact and carry back 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 conventional welded plate.
Arcoplate delivers a measurable cost per tonne benefit by the reduction of plate, maintenance and mechanical breakdown 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.
With over 30 years’ experience, ASI is a vertically integrated Australian owned and operated company. We are a manufacturer of premium quality wear products providing excellent value and cost-effective wear solutions, whilst ensuring safety in design. Alloy Steel International offers a variety of products including: Arcoplate, Arcotuff, Arcoblock, Arcobolt, WAM and many more to come.
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Arcoplate alloy steel plate has been commercially available for nearly 25 years and it started as a reaction to wear products with unpredictable wear life. Arcoplate is a wear resistant fused alloy steel plate manufactured by Alloy Steel International in Western Australia. It is a smooth dense, chromium carbide rich overlay plate manufactured by a patented production process to maximise abrasion resistance and reduce hang up no matter what the operating conditions.
Manufactured to a patented production process, all mill functions are fully computer controlled within parameters of ± 1%. This controls the chemistry and minimises the base metal dilution thereby giving predictable wear rates and component life. This patented process enables greater percentages of chromium to be used resulting in an even distribution and orientation of carbide throughout the alloy matrix. These parameters enable us to provide a much longer lasting undiluted overlay with a very low co-efficient of friction with the finished product having no weld beads to interrupt material flow.
Arcoplate can be plasma cut, rolled or pressed and all grades and thicknesses can be polished. It is high wearing and high impact resistant. Arcoplate is stress relieved in manufacture and maintains a true hardness value that is constant from the
surface right to the fusion line. As an added benefit, Arcoplate is also the only fused alloy plate that has outstanding Anti Hang-up properties. As the patented method of production allows for higher percentages of chromium and as it is produced flat with no weld bead, Arcoplate can be ordered pre-polished as an “Anti Hang-up”/wear plate. The polished surface is maintained by the natural material flow throughout the life of the plate creating smooth laminar flow that doesn’t allow micro particles to build causing hang-up/carry back on equipment which is another major cause of production loss.
Alloy Steel International’s full engineering and design service enables Arcoplate to be supplied as a complete wear kit fully designed and tailored to suit specific applications.
Tailoring our products to your operational requirements, ASI now also offers specialised custom made wear resistant Arcoplate alloys. Metals with strong affinity to carbon are strong carbide formers and can be used in production of specialised wear resistant Arcoplate alloys in varying proportions. Substantial cost increases are prevalent in manufacturing of specialised alloys due to very high additional cost inputs. Nevertheless, final product perceived high price is always much lower when compared to productivity gains in demanding high production volume, high capital and operational cost applications.
is Alloy Steel International’s newest development designed for areas that experience the most severe abrasion. Alloy Steel International is known worldwide for ability to engineer universal, specialised and custom made wear resistant alloys, – Arcoplate 1600T is no exception. Alloy Steel International’s special manufacturing process, allows Arcoplate 1600T to offer an addition of tungsten carbides dispersed consistently throughout the alloy matrix. Tungsten carbides present in 1600T alloy fill in spaces between larger chromium carbides, further reducing already tight inter-carbide spacing within the alloy matrix, in effect limiting matrix exposure to fine and coarse particle abrasion.
Alloy matrix is also made more impact resistant by other added alloying elements, ensuring stronger bond between tungsten carbides, chromium carbides and carbide retaining matrix.
1600T alloy manufacturing process is computer controlled and the unique fusion technology provides just enough base metal dilution for 100% metallurgical bond between alloy and base metal. Measured and controlled cooling rates provide perfect conditions for carbides formation, producing a dense and very tough alloy composite micro-structure.
Our manufacturing process produces complex metal carbide saturated wear resistant alloy that is: consistent, predictable and dependable. As always, every thickness of every Arcoplate alloy type – is produced in a single pass deposition ranging from 4mm Alloy on a 7mm backing plate, right through to our new 31 mm Alloy on a 13 mm backing plate. Arcoplate’s manufacturing process is superior to the outdated technology of multi-pass conventional / submerged arc welding methods which is still commonly used throughout the industry. This old technology used by other manufacturers can result in uneven heating producing high dilution, poor carbide formation, surface cracking and non-uniform hardness.