Wear Plate Solutions
CastoDurÂŽ Diamond Plate
Protection Against Abrasion, Erosion and Impact Optimal solution for large area wear protection Increased service life due to excellent homogeneity and the speciďŹ c metallurgical characteristics Easily welded and formed for custom component manufacturing A wide range of custom overlays for every industrial application
CDP® - Optimal Solution for Large Area Wear Protection
THE EUTECTIC DIFFERENCE Process – CastoDur® Diamond Plate (CDP) is welded flat with flux cored wire and a controlled “cool” welding process that together create a coating with uniform hardness and exceptional wear properties. This unique welding technique minimizes the heat input to the base plate resulting in low dilution. The fast, controlled cooling creates an overlay with a dense, extremely tough microstructure that is consistent across the plate. The monitored cooling also promotes small, controlled cross checking that does not propagate into the base metal. Conventional submerged arc methods result in uneven heating which produces high dilution, poor carbide formation and non-uniform hardness. Plates are produced on a drum and then flattened. The flattening process induces high stress which produces cracks that propagate deep into the overlay, and the base metal, and travel between the layers causing de-lamination and “chunking out” in service.
Conventional wear plates delaminate and “chunk out” during service.
22X
20
18X
14
112 & 212
16
18X
18
395N
Alloys – Eutectic is known worldwide for producing engineered alloys that combat all types of wear combinations. The company’s CDP plate is no exception. CDP wear plates are available in simple chromium carbide, complex chromium carbide, tungsten carbide and a variety of weld types, including plasma transferred arc welded, and powder fused, with hardness values ranging from 54-71 HRC.
CDP wear plates extend the service life of parts up to 20x longer than conventional wear plates.
12
6503
4666
2
4624
4
4603
6
8X
8
9X
10
0
XuperWave® – Eutectic produces unique weld bead geometry to combat fine particle abrasion. The directional change of the hardfacing on the XuperWave prevents particle tracking on the weld bead overlap and in the stress relief cracks (points most susceptible to start wearing). The zig-zag pattern of the XuperWave ensures that the stress relief cracks and weld beads are never aligned in the direction of the abrasive particle flow which means that you can cut your wear plate parts without any wasted material. This can result in a reduction in wear by up to 30% over conventional plates. Stronger, with Eutectic
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Straight Bead
XuperWave® Bead
CDP® Wear Plate - Broadest Product Selection Welded Plates: Traditional welded plate offers the optimum resistance to abrasion, erosion, impact and metal-to-metal friction. Available as-welded in straight or XuperWave® weld patterns. Fused Plates: Metal alloy powder is vacuum fused to steel plate creating a uniform hardfacing with very few stress relief cracks. Powder plates provide maximum protection even with the thinnest of deposits, making this plate lightweight, easy to handle and easily formed into a tight radius.
12 mm3
68-71
HIGHER ABRASION RESISTANCE 57% Complex chromium carbide.
17 mm3
61-64
WELDED
HIGHEST IMPACT RESISTANCE Titanium carbide.
24 mm3
54-57
13mm (1/2”)
WELDED
40% chromium carbide.
21 mm3
55-59
10mm (3/8”)
13mm (1/2”)
19mm (3/4”)
WELDED
®
4666 ®
4923 ®
4603 ®
4624 ®
112 ®
212
CORROSION
WELDED WELDED
HIGHEST ABRASION RESISTANCE NanoAlloy® submicron grain structure.
Affordable chromium carbide.
23 mm3
58-61
10mm (3/8”)
13mm (1/2”)
19mm (3/4”)
Lightweight tungsten carbide, nickel alloy matrix.
12 mm3
58-61
6mm (1/4”)
Lightweight tungsten and chromium carbide, iron alloy matrix.
12 mm3
58-60
6mm (1/4”)
65% tungsten carbide. Lowest dillution.
10 mm3
61-65
IMPACT
HARDNESS (HRC)
FUSED
395N
EROSION
G65
TYPE
DESCRIPTION
FUSED
®
®
6503
CDP 112 fused powder plate
PTA
PLATE
ABRASION
Plasma Transferred Arc (PTA) Plates: PTA welded plates contain the highest carbide content with very low dilution. They are the ultimate solution for combined erosive and abrasive wear in the most demanding applications.
* ASTM G65 average volume loss in mm3 after specimen is subjected to wear by dry sand abrasion. ** Custom thicknesses available upon request.
Complex chromium carbide plate
PTA weld pattern Stronger, with Eutectic
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PLATE THICKNESS
10mm (3/8”) 8mm (5/16”)
10mm (3/8”)
7mm (5/16”)
Primary Protection
13mm (1/2”)
19mm (3/4”)
13mm (1/2”)
19mm (3/4”)
19mm (3/4”)
9mm (3/8”) Secondary Protection
CastoLab Services - Maintenance & Repair Workshops Facing daily production problems and the shortage of skilled welders many companies are outsourcing their maintenance and repair to the experts. Eutectic has over 100 years of maintenance expertise solving heavy industry’s toughest wear problems. Our experienced CastoLab technicians will evaluate the wear phenomenon and provide you with the most reliable and cost effective solution. Often this means a combination of alloys and a specialized welding or thermal spray process only a manufacturer of the product can provide. Or, maybe a replacement wear plate part or pipe is the solution. We can provide new and semi-finished parts ready to be installed, saving you costly down time and labor in your maintenance operations. No matter what the wear or joining challenge, our fully equipped and professionally staffed CastoLab workshop can help you.
Feed Hopper
Pans
Exhaust Filter Cyclone Tubes
Feed Screw
Bulldozer Blades
Fans
Custom Boxes
Screens
Cones
YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS Eutectic Corporation N94 W14355 Garwin Mace Drive Menomonee Falls, WI 53051 USA P 800-558-8524 • F 262-255-5542 www.eutectic.com
CastoLab Services Workshop 12300 Carmen Avenue Milwaukee, WI 53022 USA P 800-558-8524 • F 262-255-5542
Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Eutectic Corporation and its affiliates shall have no liability in respect thereof. CDP 09-13 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.