Tungsten Carbide Plates

Tungsten carbide plates deliver extreme hardness, strength and wear resistance for the most demanding industrial applications. This guide provides an overview of grades, properties, manufacturing processes, sizes, finishing options and comparative assessment.

Overview of tungsten carbide plate

Tungsten carbide (WC) plates offer unmatched performance under harsh conditions:

CompositionTungsten carbide particles in cobalt binder matrix
HardnessUp to 92 HRA
Wear resistanceHundreds of times higher than alloy steels
ManufacturingPowder metallurgy compaction followed by sintering
Typical applicationsMining, mineral processing, pulp and paper
Key benefitsExtreme hardness, abrasion resistance, thermal/impact stress resilience

In plate form factors, tungsten carbide enables localized wear protection and enhanced longevity for critical equipment across extraction and bulk materials handling industries.

tungsten carbide plate Types

GradeHardness RangeKey Properties
Simplex88-92 HRAHighest hardness and wear resistance suitable for fine particle erosion
Duplex82-88 HRAGood combination of hardness and moderate impact strength
Standard78-85 HRAMost widely used grade balancing hardness, strength and cost

Grain size, binder percentage and additional alloying enables tailored grades from fine grained high hardness to more shock resistant variants.

Mechanical Properties

PropertyTypical Values
Hardness80-92 HRA
Transverse rupture strength2-3 GPa
Fracture toughness8-12 MPa√m
Young’s modulus~550 GPa

Properties vary based on carbide grain size, cobalt percentage and microstructural uniformity influenced by manufacturing process controls.

tungsten carbide plate

Size Availability

Standard plate sizes:

ThicknessPlates sizes
3-6 mmUp to 200mm x 200mm
8-11 mmUp to 100mm x 100mm

Larger plates up to 400mm x 400mm sizes possible depending on thickness. Custom machining and hole drilling services enable application-specific configurations.

Manufacturing Process

StepDescription
MillingRaw material powder particles size reduced via wet or dry milling
Spray dryingGranulation into spherical agglomerates feeding pressing operation
CompactionCold/hot isostatic pressing forms green body
DewaxRemoves polymer binders before sintering
Sintering1400-1500°C consolidates to near full density
FinishingGrinding, lapping, EDM and other machining processes

Strict process controls during compaction, dewax and sintering are vital to achieve uniform microstructure and minimize defects.

Finishing Options

TreatmentFunction
GrindingHigh precision thickness and flatness control
LappingSuperfine surface finish down to <0.5 micron roughness
PolishingMirror surface finishes
Surface coatingsEnhanced galling resistance, friction and wear performance

Combinations of mechanical, chemical and thermal finishing processes impart tailored functional enhancements aligned to wearing duty and environmental conditions.

Leading Manufacturers

Company
KennametalWidest grade rangeLarge custom plate fabrication
SandvikHigh performance oil and gas platesStringent quality assurance
CeratizitSpecialized wood and paper industry platesCost competitive
Mitsubishi MaterialsReputable mining segment platesAdvanced cobalt gradient bonds

Application-specific custom plate development leveraging proprietary grade and processing know-how. Harsher environments justify premium grades and tightly controlled QA.

Comparative Assessment

Carbon SteelsStainless SteelsCast Alloys
Wear resistanceLowMediumHigh
ToughnessHighMediumLow
FabricationEasyModerateDifficult
CostLowModerateHigh

Key Takeaways

  • Rigorous QA to minimize defects is imperative with large WC plates
  • No alternative offers wear capabilities equivalent to thick tungsten carbide
  • Proper grade matching and machining finishing is crucial

FAQs

Q: What industries use tungsten carbide plating?

A: Mining, dredging, minerals processing and pulp/paper industries leverage tungsten carbide plates for unparalleled erosion, abrasion and impact resistance

Q: How do you attach tungsten carbide plates?

A: Plates are usually affixed via shielded metal arc welding, bolt through anchors, or specially formulated high strength adhesive bonding dependent on requirements.

Q: How thick can tungsten carbide plates be made?

A: While plates over 25mm introduce quality challenges during manufacturing, specialized processes have demonstrated capability up to 75-100mm thickness ranges.

Q: Can other hard materials substitute for tungsten carbide plates?

A: Only chromium carbide overlays offer comparability with slightly lower wear rates but easier application via thermal spray coatings rather than welded plates.

know more Tungsten carbide

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