The term “wear plate” doesn’t give you much by way of steel specification.
Nor do the terms “Overlay Plate or Clad-Plate”
Wear Plate, Abrasion Resistant (AR) plate, is primarily used in heavy industrial maintenance applications. (Note that “AR” may also refer to As Rolled plate, but that is not the context we are using here). If a job is banging, clanging, screeching, or in any way loud and offensive it most likely is tearing up steel and could use some sort of hardened plate to keep things from breaking and otherwise wearing out too soon. Clad (Overlay) Plate is a Wear Plate product that is basically the combination of two products bonded together and sold as a unit. Properly matched to the application, it may significantly outlast wear plate.
If you just make wear plate really hard, it will most likely be brittle. It may be great to resist all sorts of sliding wear, but any sort of expected or unexpected vibration or impact may crack the plate. Since most applications in heavy industry involve both sliding abrasion and gouging or impact, the trick is to make a wear plate hard with some degree of ductility. The combination of hardness and ductility is called “toughness”. The nature and degree of toughness will vary with each brand of wear plate, with each chemical recipe and with each individual thermal treatment (hardening) process. Keep in mind there is no specific description of alloy content or hardness contained in the terms; wear plate, AR plate, AR400, AR500, etc. Those descriptors mostly mean that the plate is hard. My “go-to phrase” is; “Wear Plate Is Big and Ugly”. Big and ugly things are generally hard to manage. Keep that in mind, it may help you hold on to your fingers and limbs.
Now, some applications are just too mean and ugly for even highly hardened wear plate to handle. For those cases, CLAD-wear plate has been developed. There is not just one type of clad-wear plate. The overlay portion of the plate may be a heavy coating of hard weld, or a very fine diamond hard spray. For the most part, however, it will be brittle (not ductile). The bottom layer may be soft plate (A36), or it may be hardened wear plate. When these two layers are bonded together the top layer resists abrasive wear while the bottom layer holds it together and keeps it from crumbling. There are many fine grades and brands of this type of product available. Properly applied, it definitely solves big ugly maintenance problems.
When you believe you are ready to try something bigger and uglier than plain old hardened wear plate, share as much about your application as you can.
Is the medium being moved dry or wet, large or small, jagged or smooth, soft or hard?
Is it sliding dropping tumbling, or all of the above?
Is there heat involved (constant or intermittent)?
Does the medium drop onto the plate? If so, how far and how heavy is it?
Does the drop continue throughout the entire distance or does it dissipate (tumble and roll)?
(You may blend different types (grades) of clad plate along the length of your line).
The more specifics you are able to share with your vendor, the greater will be the success of matching the clad-plate to your needs. One man’s treasure in clad plate may be another’s garbage. There is that much variance.
-Howard Thomas, Dec 17th 2020
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Abrasion resistant wear plates (AR Plate) or steel liners are used in many applications where friction between two parts or materials creates degradation. Wear plates are expendable items that are used to prevent excessive wear or damage to expensive equipment.
Steel wear plates may bolt onto a machine that slides or rotates in a manufacturing process, while they can also be found where manufactured parts or minerals are regularly rubbing or abrasively contacting the surface. Wear plate is commonly a type of abrasion resistant steel plate that is considered extremely durable, especially under harsh conditions.
What types of companies usually order wear plates?
Any company that has equipment with components that slide against each other or that are exposed to abrasive or corrosive materials or impact damage such as steel mills, pipe mills, aluminum mills, chemical companies, mining, military, etc. Wear plates and liners can be made from many different materials: C954 Aluminum Bronze, 4140QT, 4340QT, AR400, and AR500 are very common.