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Premium chromium carbide overlay plate “Ultrafuse”

"Ultrafuse" 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
Ultrafuse 35	3.5-5.0% C	57-62 HRC	30-40% Primary carbides and complex carbides even distributed in austenite	Q235
	22.0-35.0% Cr
	1.0-2.0% Mn
	0.5-1.0% Si
	0.5-1.4 % Others
	Bal: Fe
Ultrafuse 65M/T	Cr-Mo-Nb-V-Ni-W	60-64 HRC	Plenty complex carbides	Q235

* Typical chemical composition as above, chemical tailored required is available also!

Grade	Properites	Vloume Fraction	Application
Ultrafuse 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
Ultrafuse 65M/T	High abrasion, high impact High temperature	Complex 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 Ultrafuse overlay plate.

Ultrafuse 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: 1000mm × 3000mm / Customized alloy specifications, plate sizes and thicknesses are available upon request！

Overlay	mm	4	6	6	8	8	10	10	12	17	20	25
Overlay	Inch	3/16	1/4	1/4	5/16	5/16	3/8	3/8	1/2	2/3	5/6	1
Backing Plate	mm	6	6	8	8	10	10	12	12	13	13	16
Backing Plate	Inch	1/4	1/4	5/16	5/16	3/8	3/8	1/2	1/2	1/2	1/2	2/3

Advantage

Bulk welded plate vs Ultrafuse

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

Wear is caused by a product flowing over a stationary surface; An uneven material surface causes microsturbulence of the product and can accelerate the wear rate of the material. The overlay offers exceeded wear life and is designed for applications in which the wear caused by severe Wear Abrasion, Erosion, low - High impact, with or without High temperatures. The weld beads on bulk weld overlay plate generates turbulence that can lead to premature and costly failure of the wear liner with no weld beads, ULTRAFUSE allows a laminar flow of the product thereby greatly reducing wear rates. Hang up / Carry Back are the terms used to describe material sticking or binding to a surface. This material build up reduces production efficiency can cause millions of dollars in lost productivity and decreases availability of plant and machinery. CASTEL's unique manufacturing process offers a smooth overlay surface ensuring a low friction coefficient and combined with excellent abrasion resistant properties greatly reduces or eliminates hang up / carry back; Our specialized design team ensures a unique and specific anti hang up / carry back solution to each and every situation; Hang up / Carry back can be caused by a number of factors including surface roughness of construction material, material surface (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 / carry back by concentrating on the factors that can be controlled.

More surprise on Ultrafuse vs other materials

ltems	Ultrafuse	Welded Overlay Plate	Q&TPlate	Ceramic	Plastics & Rubbers	Cast Manganese
High wear Resistance	√	√		√
Consistent Hardness	√			√	√
Smooth Surface Finish	√		√	√	√	√
Impact Resistance	√	√	√		√	√
Non-DirectionalApplication	√		√	√	√	√
Low Residual Stress	√		√	√	√
Easy Installation	√	√	√		√	√
Unaffected by Processing	√	√		√		√
No Size Limitations	√	√	√		√