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Premium chromium carbide overlay plate “Ultrabra

"Ultrabra" is a revelutionary chromium carbide overaly plate Castel manufacture. Due to unquie manufacturing process, it made using advanced fusion bond welding technology to apply a highly abrasive resistant chromium carbide on to a steel substrate producing consistent chemistry in many of primary carbides M7C3 higher to 30-40%, which grow up in vertical of plate and distribute in austenite evenly, and micro structure with a smooth overlay deposit. The formation of the high chromium carbide micro structure is central to producing a perfect abrasion resistant bi-metallic plate that offers properties ranging from high to severe abrasion resistance, moderate to high impact resistance and high temperature resistance that gives premium abrasion resistance and extends the maintenance cycle thereby reducing maintenance costs. With a low co-efficient of friction, it gives excellent results reducing hang up / stick in chutes, hoppers and mobile equipment. As the hardfacing surface has no weld beads, install direction required is eliminated VS traditional weld beads in vertical of material flow in general, maximizes equip availability, improve efficiency, increased productivity and lower maintenance costs.
Grade Chemistry Hardness Microstructure Substructure
Ultrabra 35 4.0-5.0% C 55-62 HRC 30-40% Primary Carbides even distributed in austenite Q235
26.0-35.0% Cr
1.0-2.0% Mn
0.5-1.0% Si
0.5 % Others
Bal: Fe
Ultrabra 65 Cr-Mo-Nb-V-W-B 55-64 HRC Complex carbides Q235
* Typical chemical composition as above, chemical tailored required is available also!
Grade Properites Vloume Fraction Application
Ultrabra 35 High abraasion
low to moderate impact
Primary carbides 30-40% Truck, dragline, excavator dozer & bucket liners,
wear plates, Hopper Linears, screens, chute liners, deflector plates, screw conveyor
flights, screed plates,fan housing liners,etc
Ultrabra 65 High abrasion, high impact
High temperature
Commary carbides 30-40% High temperature abrasion resistance up to 750℃;
Paul wurth chutes, sinter bins, high temperature screen plates
Design, material flow velocities and turbulence influence the rate of wear. Poor designing and incorrect material selection increases maintenance and production costs and reduces the availability of production equipment. Let our specialized design team consider each application by offering a specific design to match each application by incorporating smooth surface Ultrabra overlay plate.

Ultrabra can be supplied in a range of thickness and selecting the correct plate thickness helps in minimizing addition material weight without compromising wear life.
Standard coated areas after cutted: 1200mm × 3000mm / Customized alloy specifications, plate sizes and thicknesses are available upon request!
Overlay mm 3* 4* 4 6 6 8 8 10 10 12 17* 20*
Inch 1/8 3/16 3/16 1/4 1/4 5/16 5/16 3/8 3/8 1/2 2/3 5/6
Backing Plate mm 3* 4* 6 6 8 8 10 10 12 12 12* 12*
Inch 1/8 3/16 1/4 1/4 5/16 5/16 3/8 3/8 1/2 1/2 1/2 1/2
Advantage

Ultrabra vs bulk welded plate

Manufacturing Process Advantages
Surface treatment before hardfacing Shot blasting Clean base Metal Surface to enhance fusion process
Base plate pre-heat Pre-heat to set temperature Pre-heat to reduce residual stress
Temperature held after weld Holding temperature for slow cooling process Post heat to reduce residual stress at fusion line
Cooling during welding Slow Cool Enhances mechanical strength of the base plate
Finished plate flatness Even ±3mm per 1.5 linear metres
Surface finish Smooth Designing for directional flow of material not necessary
Friction co-efficient Low Excellent for reducing or eliminating hang up or carry back
Visible surface weld bead No visible beads Smooth surface without weld beads
Single pass overlay depth 3 to 12mm Uniform microstructure and hardness
Fusion dilution depth 0.5 - 1.0 mm Low overlay dilution with backing plate. Wear rates become consistent and predictable
Microstructure & Hardness consistency Uniform down to fusion line Consistent and predicable wear rates
Operating temperature <600 ℃ Excellent high temperature wear rates