Wear Plate - Production, Fabrication and Installation

Trimay wear 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

Trimay Wear 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

Trimay wear 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 sizes specified.

Trimay wear 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 20mm-30mm, respectively.

Fabrication of Wear Plates

Trimay Wear 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

About Trimay

Trimay 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.