Composite Hardfaced Plates and Components
Composite hardfaced plates are mainly used in applications to improve the service life of the components against abrasion, impact, erosion, and sometimes a combination of those mechanisms at elevated temperatures or in corrosive environments. They are commonly produced in the form of standard plates and or cut and shaped parts to suit applications.
The industry adopts various alloys ranging from chromium carbides to complex tool steel alloys with primary carbides. Aliaj Joosh has the knowledge in offering:
Composite hardfaced plates types
Composite hardfaced plates are mainly used in applications to improve the service life of the components against abrasion, impact, erosion, and sometimes a combination of those mechanisms at elevated temperatures or in corrosive environments. They are commonly produced in the form of standard plates and or cut and shaped parts to suit applications.
The industry adopts various alloys ranging from chromium carbides to complex tool steel alloys with primary carbides. Aliaj Joosh has the knowledge in offering:
Large hardfaced components
Aliaj Joosh fabrication shop is one of the largest hardfaced components manufacturing shop in the region with more than 20 years of experience. With close partnership with major OEMs in steel , Cement and Mining industries we are proud to be able to manufacture and supply more than 80% of the large hardfaced components to the new and upgrading projects.
Our engineering team has done many research and development works together with end users to design these components with the ideal and best wear resistant material and geometry. The complete study on each equipment from abrasion and erosion factors, raw material chemistry, component geometry and operation temperature enable us to design ideal resistant alloy, hardfacing procedures and advance automation techniques. Aliaj Joosh equipped and offers:
- Manufacturing of wide range of various hardfaced plate with range of chromium carbides to complex carbides
- Fully automatic and robotic welding equipment and robust manufacturing scheme to deliver highest quality plates
- Fabricating hardfaced cut-to-shape components according to drawings
- Rolling and bending machines
- Stud welding equipment
- CNC underwater cutting machine to reduce tempering risk during cutting and in result minimising the risk of hardness reduction in cut areas
Cut-to-shape hardfaced plate
Standard Hardfaced plates are required to be cut and shaped according to the project specification and shop drawings. Because of the microstructure and mechanical properties of these products, cutting and shaping them is not as straight forward as carbon steel plates.
The most practical and economical process to be is to cut the composite hardfaced plates is automatic underwater equipment.
Aliaj Joosh has the most advanced CNC underwater plasma cutting machine which guarantees the best practice to cut and shape these plates. The advantage of our solution is;
- Reduces heat input on edges of cut areas and minimising the risk of tempering
- Guarantees the accurate and precise dimensions
- Homogenous structure and hardness on the edges and hardfaced plate surface
- Higher speed and productivity
- Better surface and edge quality for further fabrication process
Subject to the shape of the products, cut-to-shape plates are also required to be formed, rolled and assembled. Alia Joosh uses advanced techniques and equipment to make sure that the products are fabricated according to project specification with highest quality and durability.
Fixing and Assembly
After fabricating the parts, they are required to be fixed on the frames installed and accordingly on the customer’s equipment. Fixing and assembly can be done by welding or studs. The most common practices are:
Welded studs: Threaded sockets are welded by stud bolt machine at the back of the parts, eliminating the risk of contaminating the surface of the hardfaced plate and enhancing the quality of the cut-to-shape parts.
Insert CSK bolt: In this method the hole is cut by CNC plasma underwater cutting equipment ensuring the highest quality. During welding of inserts, it is important not to get the weld metal contaminated with hardface material.
