"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 base plate and distribute 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.
Low stress or scratching abrasion is the most predominate wear characteristic with the steel being abraded away by the abrading material removing slivers from the wearing steel.
The length of the metal sliver removed varies based upon the microstructure and bulk hardness of the material being abraded.
Laboratory & Field tests show Ultrabra-35 will outlast
Conventional weld overlay by a factor > 2:1Quenched & tempered steel plate by a factor > 5:1
ASTM G65 Dry Sand Rubber Wheel Test
The dry-sand, rubber-wheel apparatus (DSRW) is a low stress or scratching abrasion test that is the most predominate test for the mining industry. The ASTM G65 test characterises materials
in terms of weight loss under a controlled set of laboratory conditions. Actual field conditions may be influenced by other factors Such as impact, corrosion or heat. The ASTM G65 test gives a
valuable insight into field performance
| Products |
Force |
Rotation |
Rate |
Dia of wheel |
Sand size |
Loss Weight |
Sample |
10 on 10
Ultrabra-35 |
8.8Kg |
3000r,6000r |
120r.p.m |
250mm |
#6 |
300g/min |
20*20*40(mm) |
| No |
Grade |
Loss(g) |
Rate in loss |
| 3000r |
6000r |
#1 / #2 |
| #1 |
Ultrabra-35 |
0.1041 |
0.199 |
5.29 |
| #2 |
Q&T 500 |
0.4252 |
1.052 |
Ultrabra vs bulk welded plate
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.！
Turbulence and Wear
Wear is caused by a product flowing over a stationary surface. An uneven material surface causes microturbulence of the product and can accelerate the wear rate of the material
The weld beads on bulk weld overlay plate generates turbulence that can lead to premature and costly failure of the wear linerWith no weld beads, Ultrabra allows a laminar flow of the
product thereby greatly reducing wear rates.
Reduction of Carry Back - Hang Up/Stick
Pre-Polished Ultrabra Reduction of “Hang up / stick - Carry Back”
Pre-polished Ultrabra Friction Co-Efficient
| Material |
Wall Pressure(9.35kpa) |
Wall Pressure(13.1kpa) |
Wall Pressure(13.1kpa) |
Wall Pressure(9.35kpa) |
| Pre-polished Ultrabra |
0.33 |
0.34 |
18.3 |
18.6 |
| QT400BHN |
0.43 |
0.44 |
23 |
23 |
| Utility Stainless steel |
0.44 |
0.43 |
23.3 |
23.3 |
Hang up / Carry back can be caused by a number of factors including surface roughness of construction material, materila surface features (smooth or uneven), design and properties of the
materials being transported (normally uncontrollable). To achieve increased production our aim is to eliminate or greatly minimise hang up / caryy back by concentrating on the factors that can
be controlled. Buildup is costly as it reduces production efficiency, can cause millions of dollars in lost productivity and decreases availability of plant and machinery.Most material with either a
high content of clay or water will have some type of hang up carry back problem so castel try to approach every hang up / carry back application uniquely.
