Chromium Carbide
Overlay Plate
A bimetal wear plate combining a mild steel substrate with a chromium carbide weld overlay -- delivering HRC 58-65 surface hardness, Cr₇C₃ microstructure, and up to 20× the abrasion life of carbon steel in the most demanding bulk-handling and processing environments.
What Is Chromium Carbide
Overlay Plate?
Chromium carbide overlay (CCO) plate is a bimetal composite wear plate manufactured by depositing a chromium carbide-rich alloy layer onto a mild steel base plate using automated open-arc or submerged-arc welding processes. The result is a plate with two distinct functional zones: a tough, weldable substrate that provides structural strength and formability, and a hard overlay layer that resists severe abrasion, erosion, and impact.
The overlay alloy contains 25-35% chromium and 4-6% carbon, which precipitates a dense network of Cr₇C₃ primary carbides in a eutectic matrix during solidification. These carbides -- with a hardness of approximately HV 1,400-1,800 -- are the primary source of wear resistance. The resulting plate surface achieves HRC 58-65, providing abrasion resistance up to 20 times greater than carbon steel and 5 times greater than heat-treated alloy steel.
Why Choose HALDEN CCO Wear Plate?
20 dedicated production lines, 90,000 m² annual capacity, and deep process know-how translate into consistent quality, competitive lead times, and full custom capability.
20 fully automated CCO production lines delivering 90,000 m² per year. Consistent overlay parameters -- current, voltage, travel speed -- are monitored and logged on every run, ensuring batch-to-batch repeatability.
Every batch is tested with Rockwell hardness testers and SPECTROMAX materials analysis spectrograph. Actual alloy chemistry and HRC values are recorded and available on request, not just stated in spec sheets.
Beyond flat plate supply, HALDEN fabricates finished wear liners, chute liners, wear pipes, elbows, and custom wear parts. Cutting, bending, drilling, rolling, stud welding, and welded assembly all performed in-house.
Wear products certified for Europe, Americas, Australia, and Asia. Export documentation, material certificates, test reports, and third-party inspection support available for all orders.
Free sample service, OEM design, pre-sale solution matching, and 8-hour response guarantee. HALDEN's technical team assists with overlay grade selection, thickness specification, and installation design.
More than 17 years supplying wear solutions to cement, mining, power generation, and bulk-handling industries. Deep application knowledge across hundreds of equipment types and wear environments worldwide.
Technical Specifications
Standard CCO plate specifications. Custom alloy grades, overlay thicknesses, and substrate materials available on request.
| Element | Content (%) | Role |
|---|---|---|
| Chromium (Cr) | 25 - 35% | Primary carbide former |
| Carbon (C) | 4 - 6% | Hardness driver |
| Manganese (Mn) | 0.5 - 1.5% | Toughness / deoxidizer |
| Silicon (Si) | 0.5 - 1.5% | Fluidity / oxidation resistance |
| Iron (Fe) | Balance | Matrix base |
| Property | Value |
|---|---|
| Surface Hardness (Overlay) | HRC 58 - 65 |
| Carbide Hardness (Cr₇C₃) | HV 1,400 - 1,800 |
| Max Service Temperature | 600°C (1,112°F) |
| Density (Overlay) | ~7.6 g/cm³ |
| Substrate (Standard) | Q235 / A36 mild steel |
| Overlay Layers | 1 layer / 2 layers |
| Abrasion Life vs. Carbon Steel | Up to 20× |
| Total Thickness | Overlay Thickness | Substrate Thickness | Standard Sheet Size | Max Sheet Size |
|---|---|---|---|---|
| 6+4 mm | 4 mm | 6 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| 8+6 mm | 6 mm | 8 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| 10+6 mm | 6 mm | 10 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| 12+8 mm | 8 mm | 12 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| 16+8 mm | 8 mm | 16 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| 20+10 mm | 10 mm | 20 mm | 1,400 × 3,000 mm | 1,500 × 3,500 mm |
| Custom | Per requirement | Per requirement | -- | Contact HALDEN |
* Substrate notation: substrate thickness listed first, overlay thickness listed second (e.g., 6+4 = 6 mm substrate + 4 mm overlay). Custom sizes, double-sided overlay, and special substrate grades available on request.
Microstructure &
Wear Mechanism
The wear resistance of CCO plate originates from its unique solidification microstructure. During the overlay welding process, the high chromium and carbon content drives the precipitation of Cr₇C₃ primary carbides -- elongated, rod-shaped crystals oriented perpendicular to the plate surface -- embedded in a chromium-rich eutectic matrix.
This perpendicular carbide orientation is critical. When abrasive particles contact the surface, they encounter the hard carbide ends rather than the softer matrix, dramatically reducing material removal rate. The result is a wear mechanism dominated by micro-cutting resistance rather than plastic deformation, making CCO plate particularly effective against high-stress abrasion, fine-particle erosion, and sliding wear.
* Based on dry sand rubber wheel abrasion test (ASTM G65). Actual values depend on abrasive type, particle size, and impact angle.
Manufacturing Process
HALDEN's 20 automated CCO production lines operate under controlled welding parameters to ensure consistent overlay chemistry, hardness, and bond integrity across every plate.
Steel plate surface cleaned, leveled, and positioned on automated welding bed.
High-chrome flux-cored wire fed at controlled rate through automated welding head.
Automated FCAW open-arc overlay deposited in parallel passes at controlled heat input.
Plates cool under controlled conditions to manage residual stress and surface craze cracking.
Pressing machine corrects any plate distortion from welding heat, ensuring flatness tolerance.
Hardness testing, spectrograph analysis, dimensional check, and batch documentation before shipment.
Fine surface craze cracks (stress relief cracks) are a normal characteristic of chromium carbide overlay plate. They are inherent to the solidification and cooling of the high-hardness overlay and do not affect wear performance or structural integrity. Craze cracks do not propagate into the substrate under normal service conditions.
Fabrication
Capabilities
HALDEN supplies CCO plate not only as raw flat plate, but also as fully fabricated wear components ready for direct installation. All secondary processing is performed in-house, eliminating coordination across multiple suppliers and ensuring dimensional accuracy from plate to finished part.
CNC plasma cutting to ±1 mm tolerance. Complex profiles, holes, slots, and custom shapes cut directly from CCO plate without delamination.
CCO plate bent with overlay on the outer radius. Minimum bend radius and overlay crack behavior confirmed per plate thickness before forming.
Countersunk and through-holes drilled in the substrate for stud or bolt attachment. Hole patterns per customer drawing or standard liner layouts.
Studs welded to the substrate back face for quick-change liner systems. Stud size, pitch, and pattern customized to equipment interface.
CCO plate rolled into cylindrical or conical sections for wear pipe liners, cyclone liners, and curved chute components.
Cut and formed CCO sections welded into complete wear assemblies -- chute boxes, pipe elbows, crusher liners, and other complex wear structures.
Applications by Industry
CCO plate is specified wherever abrasion, erosion, or impact shortens equipment life and drives maintenance cost. Below are the primary industries and equipment types served by HALDEN.
Ore chutes, transfer points, crusher liners, screen panels, conveyor discharge chutes, and slurry pipe liners in iron ore, copper, coal, and aggregate operations.
- Crusher Feed Chutes
- Conveyor Transfer Chutes
- Slurry Pipe Liners
- Bucket Elevator Boots
Raw mill chutes, preheater ducts, clinker cooler plates, coal mill components, and kiln inlet/outlet liners subject to high-temperature abrasion from clinker, raw meal, and coal.
- Clinker Cooler Plates
- Preheater Cyclone Liners
- Coal Mill Chutes
- Separator Liners
Coal handling chutes, pulverizer components, classifier liners, fly ash handling systems, and flue gas duct liners in thermal power plants and coal preparation facilities.
- Pulverizer Throats
- Coal Chute Liners
- Fly Ash Pipe Bends
- Fan Blade Liners
Sinter plant chutes, blast furnace hoppers, port grab bucket liners, bulk terminal conveyor systems, and glass batch plant components exposed to abrasive raw materials.
- Sinter Chute Liners
- Grab Bucket Liners
- Glass Batch Chutes
- Blast Furnace Hoppers
Product Forms
From flat CCO plate to fully fabricated wear assemblies -- HALDEN delivers in the form your installation requires.
Standard flat CCO plate supplied to size. Available in standard sheet dimensions or custom-cut to drawing. Direct replacement for existing liners or new installation design.
- Standard & custom sizes
- Drilled stud holes available
- Countersunk bolt holes
CCO plate sections cut, bent, and assembled into complete chute liner kits or box assemblies. Supplied with all fixing hardware and installation drawings on request.
- Transfer chute liners
- Hopper box liners
- Skirt board liners
Custom-profiled CCO liners for jaw crushers, cone crushers, impact crushers, and hammer mills. Fabricated to match OEM profiles or customer drawings.
- Jaw crusher feed liners
- Impact crusher liners
- OEM profile matching
CCO plate rolled and welded into cylindrical wear pipe sections for slurry, fly ash, and bulk material conveying. Available with flanged or plain ends.
- DN 80 - DN 1,200
- Flanged or plain ends
- Custom lengths
Fabricated CCO elbows for 45°, 90°, and custom-angle pipe bends. Reinforced outer-radius wear zone with increased overlay thickness where abrasion is highest.
- 45° / 90° / custom angles
- Reinforced outer radius
- Flanged connections
Any shape, profile, or assembly not listed above. HALDEN's engineering team works from your drawings, failed parts, or application description to design and fabricate custom CCO wear components.
Discuss Your RequirementQuality Control
HALDEN is certified under ISO 9001 quality management and ISO 14001 environmental management systems. Every batch of CCO plate is tested and documented before dispatch -- not spot-checked, but batch-verified.
For industrial wear applications, quality is not a compliance exercise -- it is a direct determinant of service life, maintenance interval, and total cost of ownership. HALDEN's QC process is designed to give buyers verifiable confidence in every plate delivered.
Overlay alloy chemistry verified by optical emission spectrograph. Chromium, carbon, manganese, and silicon content confirmed against specification for every production batch.
Surface hardness measured at multiple points per plate using calibrated Rockwell hardness testers. HRC values documented and available in material test reports.
Abrasion performance evaluated per ASTM G65 protocol. Mass loss data used to verify wear resistance relative to reference materials and confirm batch-to-batch consistency.
Portable ultrasonic hardness testers used for in-process and final inspection of overlay hardness uniformity, including areas near plate edges and weld seams.
Microstructure examined by optical microscope to verify Cr₇C₃ carbide morphology, distribution, and overlay-substrate interface integrity. Micrographs available on request.
Packaging & Delivery
HALDEN packages CCO plate and fabricated wear components for international export. All packaging is designed to prevent surface damage during ocean freight and protect overlay integrity through handling at destination.
(Standard Orders)
Preferred
Standard Terms
Guarantee
How to Select the Right CCO Plate
CCO plate selection depends on four key variables. Use this guide to narrow your specification before contacting HALDEN's technical team.
| Overlay | Application |
|---|---|
| 3-4 mm | Light abrasion, fine particles, low-impact chutes |
| 5-6 mm | Medium abrasion, standard conveyor and chute liners |
| 7-8 mm | Severe abrasion, coarse ore, crusher feed zones |
| 10+ mm | Extreme wear, primary crusher liners, high-impact zones |
Not sure which specification is right for your application? HALDEN's technical team will review your wear environment and recommend the optimal grade, thickness, and supply form.
Get a Free Technical Recommendation
Frequently Asked
Questions
Common questions from procurement managers, maintenance engineers, and project buyers evaluating CCO plate for wear-critical applications.
Ask a Technical QuestionWhat is the difference between CCO plate and AR (abrasion-resistant) plate?
Are the surface cracks on CCO plate a defect?
Can CCO plate be welded to a structure?
Can CCO plate be used at high temperatures?
What is the minimum order quantity for CCO plate?
How do I specify CCO plate for a purchase order?
Request CCO Plate
Pricing & Technical Review
Tell us your application, required size, thickness, and quantity. HALDEN's technical team will respond within 8 hours with pricing, a technical recommendation, and free sample availability.
HALDEN Chromium Carbide Overlay Plate -- HRC 58-65 hardness, Cr₇C₃ microstructure, 20 production lines, 90,000 m²/year capacity, and full in-house fabrication into wear liners, chute liners, crusher liners, wear pipes, elbows, and custom assemblies. One partner for CCO plate supply and finished wear component delivery.