Engineered composite wear plates
Our complete range of wear-resistant products covers every application from light abrasion to extreme impact and heat.
Overlay wear plates
The overlay plate is manufactured by cladding a wear-resistant material to a mild steel base plate. The high volume of rich carbides fuses to the base plate and is evenly distributed throughout the uniform overlay thickness, creating a bimetallic material with high wear resistance and good processability.
TW100
Standard chromium carbide overlay plate designed for severe abrasion and low-to-moderate impact.
TW100 is a chromium carbide composite cladding that is fusion-bonded to a mild steel backing plate. A very high volume of chromium carbides is fused to the base plate and is evenly distributed throughout the uniform thickness of the deposit. This creates a bimetallic material with exceptional abrasion resistance, while still retaining enough ductility to allow forming and welding.
Application. Excellent resistance in severe abrasion and low to moderate impact environments.
| Property | Value |
|---|---|
| Minimum thickness | 2 + 2 mm |
| Standard plate size | 1400 × 2000 mm |
| Element | Content |
|---|---|
| Carbon | 3.5 – 7.5 % |
| Silicon | 0.5 – 3.0 % |
| Manganese | 0.5 – 3.0 % |
| Chromium | 30 – 40 % |
| Others | Balance |
TW200
Premium bimetallic plate engineered for enhanced structural integrity.
TW200 is a chromium carbide composite cladding manufactured with an advanced welding process. The material features a seamless fusion bond between chromium carbide composites and a tough mild steel backing, forming a bimetallic structure. With an exceptionally high concentration of chromium carbides thoroughly fused to the base plate and evenly distributed throughout the uniform thickness, TW200 delivers outstanding abrasion resistance, retained ductility for forming and welding, and reliable performance in harsh environments.
Application. Reliable performance in harsh environments where bond integrity is critical.
| Element | Content |
|---|---|
| Carbon | 3.5 – 7.5 % |
| Silicon | 0.5 – 3.0 % |
| Manganese | 0.5 – 3.0 % |
| Chromium | 30 – 40 % |
| Others | Balance |
TW300
Advanced plate alloyed with niobium, molybdenum and vanadium, built for extreme abrasion combined with heavy impact.
TW300 is a composite cladding consisting of chromium carbide, niobium carbide, molybdenum carbide, vanadium carbide and titanium carbide, fusion-bonded to a mild steel backing material. A very high volume of these complex carbides is fused to the base plate and evenly distributed throughout the uniform thickness of the deposit. The result is a bimetallic wear plate offering excellent abrasion resistance and retained ductility for forming and welding.
Application. Ideal for use in high-abrasion and medium to high impact environments.
| Element | Content |
|---|---|
| Carbon | 3 – 7.5 % |
| Silicon | 0.5 – 3.0 % |
| Manganese | 0.5 – 3.0 % |
| Chromium | 21 – 35 % |
| Mo + Nb + Ti + V + W | ≥ 2.5 % |
| Others | Balance |
TW600
Chromium and tungsten carbide composite cladding engineered for the most extreme abrasion environments.
TW600 is a chromium carbide and tungsten carbide composite cladding that is fusion-bonded to a mild steel backing plate. A very high volume of complex carbides is fused to the base plate and uniformly distributed through the full thickness of the overlay, creating a bimetallic material that combines exceptional abrasion resistance with retained ductility for forming and welding.
Application. Specifically engineered for extremely severe abrasion environments, providing long service life even under the harshest wear conditions.
| Element | Content |
|---|---|
| Carbon | 4.4 – 7.5 % |
| Silicon | 0.5 – 3.0 % |
| Manganese | 0.5 – 2.0 % |
| Chromium | 23 – 40 % |
| Tungsten (W) | 2 – 7 % |
| Others | Balance |
TW-F
Seamless, wave-free overlay plate with an ultra-smooth finish that prevents material hang-up and carry-back.
TW-F Smooth Surface plates are produced by depositing a high-chromium, high-carbon overlay onto a mild steel base metal using an improved welding technique. This process creates a uniform chemistry and microstructure with a smooth surface and no visible welding beads, which minimises material hang-ups in chutes, hoppers and other handling equipment while retaining ductility for forming and welding.
Application. Suitable for applications where there are a lot of hang-ups in highly abrasive working environments.
| Grade | C (%) | Si (%) | Mn (%) | Cr (%) | W (%) | V (%) | Mo+Nb+Ti+V+W (%) | Others |
|---|---|---|---|---|---|---|---|---|
| TWF1 | 3 – 6 | 0.5 – 2.5 | 0.5 – 2.5 | 23 – 35 | Balance | |||
| TWF2 | 3 – 6 | 0.5 – 2.5 | 0.5 – 2.5 | 20 – 35 | ≥ 2.5 | Balance | ||
| TWF3 | 3 – 6 | 0.5 – 2.5 | 0.5 – 2.5 | 20 – 35 | 2 – 7 | Balance | ||
| TWF4 | 4 – 6 | 0.5 – 1.5 | 1.0 – 2.0 | 25 – 35 | 3 – 6 | Balance |
Customised to your requirement
When none of the standard grades matches your wear pattern, TW-X plate is built to the specification your application demands.
Discuss your casePlate dimensions and features
| Property | Value |
|---|---|
| Standard plate size | 1400 × 3000 mm · 1500 × 3000 mm · 1400 × 3700 mm · 2000 × 3000 mm · 2100 × 3500 mm |
| Coating thickness | 30 – 80 mm |
| Base material thickness | 3 – 150 mm |
Other sizes and thicknesses available on request.
Features
- High volume primary chromium carbide evenly distributed
- Flat surface with excellent plate flatness
- Macro-hardness: 58 – 63 HRC
- Multiple grades available to suit different applications
- Excellent wear performance (ASTM G65 procedure A)
- Larger sheet size to extend plate utilisation
- Uniform plus tolerance thickness
- Good formability due to even stress relief in overlay
Overlay wear pipes
Overlay wear pipe is designed to withstand tough, abrasive materials to extend service life. The hard-face welding forms the wear layer, which consists of a large volume of chromium carbide and provides high hardness. It is an ideal wear solution for extreme applications with maintenance problems, combining severe abrasive wear resistance with moderate to low impact resistance. Different specifications and sizes can be processed, which is convenient for making replacements.
Specification
- Wide range of base pipe thickness and overlay thickness options
- Length up to 40 feet
- Diameter from 3 inches
End attachment options
- Standard flanges (150#, 300#, 600#)
- Weld rings
- Victaulic ends
Custom geometries of elbows, tees, wyes, concentric or eccentric reducers, valve bodies, U-bends and cross pieces are available on request.
Materials conveyed
Ash, coal, sand, cement, stone, gravel, limestone, magnetite, mill scale, mine tailings, ores, raw kiln feed, slurry, mud and slag.
Custom fabrication
Full-service in-house fabrication, including plasma cutting, rolling, bending and structural welding. We deliver ready-to-install components based on your drawings, ensuring the protective wear layer maintains its structural properties.
The backing steel plate provides Tough Weld plates with structural integrity, which means our overlay plates can be fabricated without damage to the welding overlay, regardless of the shape and complexity of the structure. Tough Weld has the capability to manufacture cut-to-size wear parts.
Fabrication includes
- Cutting
- Forming
- Welding
- Stud attachment
- Assembling
Applications by industry
The industries we supply and the equipment our plates and pipes protect.
Not sure which grade you need?
Send us the wear pattern, the material and the geometry. We will specify the plate.