CCO Plates
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Chromium Carbide Overlay (CCO) Plates: High-Wear Protection for Extreme Environments
Chromium Carbide Overlay (CCO) plates are advanced wear-resistant materials formed by welding a hard-facing layer of chromium carbide alloy onto a mild steel or low-alloy steel base. Designed to endure extreme abrasion and moderate impact, these plates deliver superior wear performance, extending the life of industrial equipment exposed to heavy-duty conditions.
Key Applications:
- Mining and Quarrying:
- Ore Chutes & Transfer Points – Withstand the sliding and impact of abrasive rocks and ore.
- Crusher Liners & Hoppers – Resist gouging, erosion, and material scouring under high impact.
- Excavator & Loader Buckets – Extend service life in high-wear zones such as bucket lips and side walls.
- Bulk Material Handling Systems:
- Conveyor Skirt Liners & Chute Liners – Reduce replacement frequency and maintenance downtime.
- Silos, Feeders, and Bins – Prevent wall wear from constant material movement.
- Drag Chain Conveyors & Discharge Chutes – Increase flow reliability and protect structural integrity.
- Cement, Steel, and Power Plants:
- Clinker Handling Systems – Tolerate extremely abrasive hot materials.
- Coal Bunker Liners – Reduce wear from coal flow and minimize shutdowns.
- Ash Discharge Systems – Handle both abrasion and heat effectively.
Manufacturing Process:
- Base Plate Preparation:
- A mild steel or low-alloy steel plate is selected as the substrate.
- The surface is cleaned, leveled, and prepared for welding.
- Hardfacing Overlay Welding:
- Chromium carbide alloy is deposited on the base plate using open arc welding, submerged arc welding (SAW), or plasma transferred arc (PTA).
- A series of weld beads are applied in layers (single or multiple), forming a hard, wear-resistant surface.
- Post-Weld Treatment:
- Plates are cooled under controlled conditions to minimize cracking.
- Surface cracks (cross-checking pattern) are typical and do not affect performance.
- The plate is cut to size using plasma, water jet, or laser cutting.
Properties of the Overlay:
- Microstructure: The overlay contains hard chromium-rich carbides (Cr₇C₃) dispersed in a tough austenitic matrix.
- Hardness: Typically in the range of 55–65 HRC (Rockwell Hardness), offering excellent resistance to sliding wear.
- Overlay Thickness: Ranges from 3 mm to 20 mm, depending on the application.
Benefits of CCO Plates:
Exceptional Abrasion Resistance – Up to 10 times more wear life than mild steel or hardox alone.
Cost-Effective – Longer service life reduces downtime and maintenance costs.
Customizable – Can be tailored in thickness, pattern, and size to match specific wear zones.
Strong Bonding – Metallurgically bonded overlay ensures durability under thermal or mechanical stress.
Versatile Installation – Can be welded, bolted, or clamped onto equipment surfaces.
Cross-Check Cracking – Allows stress relief, preventing catastrophic failure in high-wear zones.
Available Formats:
- Flat Sheets and Plates
- Pre-formed Curved Sections (for chutes, pipes, and elbows)
- Cut-to-Size Components (with bolt holes or fabricated into liners)
- Wear Pads and Liners (for direct installation)
CCO plates are a go-to solution in industries facing high-stress abrasion and moderate impact conditions. Their unique combination of hardness, toughness, and adaptability makes them essential for prolonging equipment life in mining, cement, power generation, and material handling operations. Whether used as liners, wear plates, or structural reinforcements, CCO plates ensure consistent performance and significant maintenance savings.
