Table of ContentsIntroductionWear
Plate Welding ProcessQuality Testing of Wear
PlatesCapabilities of Wear Plates
Size and Thickness of Wear
Plates Fabrication of Wear
Plates Installation Process
for Wear Plates About Trimay
plate and pipe is designed to combat the rigors of high wear environments
and is a viable solution to the problem of wear in many industries. By reducing
wear, service life of components is extended reducing downtime allowing the user
to concentrate on production rather than maintenance and in the process
increasing efficiency. Outlined below are some industries and examples of where
they can benefit from changing over to using Trimay wear
plate in place of more traditional materials.
Wear Plate Welding Process
Plate produces wear plates using solid- core weld wires and the bulk overlay
submerged-arc welding process. Each wear plate manufacturing table is capable of
turning around a maximum of three wear plates at a time. The process is overseen
by a welder whose responsibility includes maintaining a welding surface free of
impurities, a constant flux flow and a steady wire-feed rate.
The supervising welder is also responsible for adjusting the welding
parameters such as voltage and amperage to ensure that a 30% dilution rate is
maintained and the strength of the base plate remains unaltered. Several
variables including base plate thickness, overlay thickness and overlay type are
responsible for controlling these factors.
Quality Testing of Wear Plates
After the production of wear plates using the above process, Trimay sends
the products for quality testing. Every wear plate produced is subject to
stringent quality inspections to ensure that it adheres to the defined
standards. The Rockwell hardness (HRc) test results of each plate is documented
and every plate can be traced back to the powder batch and further back to the
MTR of the base steel batch.
Capabilities of Wear Plates
Size and Thickness of Wear Plates
plates are available in two standard sizes, namely, Narrow and Regular. The
plate and overlay lengths of both types of plates are 3.05m. The plate width of
the narrow variant is 1.22m while its overlay width is 1.14m. The regular-sized
wear plates come with a plate width of 1.52m and overlay width of 1.42m.
Regular-size T157 wear plate shown above
The thicknesses of Trimay wear plates depend on the type of overlay. Overlays are
usually formed on stainless steel, 44W (300W) carbon steel, or 516 Grade 70 for
pressure applications. Trimay undertakes to fabricate wear plates for all types and
plates are available across several thickness specifications. The Chrome
overlay type comes in three types, namely, T138 with 9mm-18mm thickness range;
T156 with 10mm-30mm thickness range; and T157 with 11mm-33mm thickness range.
The Complex overlay T161 is specified with a thickness range from 10mm to 30mm
while the Tungsten overlay T170 can be custom made. There are four varieties of
overlays available under the New Nano type, namely, T171*-3mm,
T171*-6mm, T171*-8mm and T171*-13mm. The
thickness ranges for these products are 8mm -24mm, 10mm-24mm, 13mm-25mm and
Fabrication of Wear Plates
Plate’s products can be delivered in stacks of plate, or be fabricated
depending on specifications. While the plates can be formed or rolled using
press brakes or cut using water jet or plasma arc, they cannot be flame cut. The
parameters determining the formability of a plate are its thickness and the
position of the weld, whether it must be on the outer or the inner diameter of
the plate. For low precision applications, carbon arc gouging method can be used
to remove the overlay material. These overlays cannot be machined and upon
requirement, EDM or grinding methods can be used for surface finishing.
Installation Process for Wear Plates
Fillet or plug welding is deployed by Trimay Wear
Plates for installation. Alternatively, the wear can be fabricated or bolted
with inserts as a method of installation. All installation must be mounted with
the appropriate welding wire to ensure that the weld seam and wear on the plate
is even. For overlay types T161 and T161i, the recommended weld wire is TWP61w
whereas those for T138, T156, T170 and T171* are TWP56w, TWP57w,
TWP70w and TWP71w, respectively. Both TWP57w and TWP61w weld wires are
applicable for the T157 overlay type while overlays of stainless steel and
cushion layers will require the TWP1968w weld wire.
Trimay-lined shovel with Trimay bucket teeth
develops and manufactures the highest quality wear overlays for customers
seeking to maximize efficiency by extending the life of equipment, parts and
pipelines exposed to severe wear conditions. Trimay
achieves its high-quality standard through research and development, partner
companies and exclusive suppliers, as well as through in- house experimentation
and process optimization.
* Developed by Trimay Wearplate Ltd. using NanoSteel® Technology
under license from The NanoSteel® Company, Inc.
This information has been sourced, reviewed and adapted from
materials provided by Trimay Wear Plate Ltd
For more information on this source please visit Trimay Wear Plate.