Chromium Carbide Overlay - Built to Last in the World of Metals

Chromium carbide is a compound that is composed of various combinations of chromium and carbon. Its outstanding strength, its ability to retain that strength under even high - temperature exposure, and its ability to resist corrosion render it an ideal additive material in the steel industry. When steel plating (or any other metal alloy) is overlaid with it, it becomes extremely hard and durable.

These advantages add up to chromium carbide enjoying a wide range of applications and uses, including the surface treatment of steel components. Steel plates that are overlaid with it "are meant to be welded onto existing plate structures or machinery in order to improve performance," Wikipedia explains.

Materials World, the member magazine of the Institute of Materials, Minerals and Mining provides a long list of applications. Among them are the following:

    Wear Resistant Coatings - The hardness of chromium carbide helps it to protect parts that are coated with it. Two of the advantages of these coatings are that they are inexpensive and easily applied via welding or thermal spraying. Cutting tools are just one of the items that are formed with chromium carbide overlay.

    Welding Electrodes - More and more often chromium carbide welding electrodes are taking the place of outdated carbon - containing electrodes. That is because they produce better and more consistent results. They also provide a wear - resistant layer to the electrode, up to 250% superior to the earlier carbon - containing electrode, and result in less variation between welds. The application in which the electrodes are most often seen is the "hardfacing of conveyor screws, fuel mixer blades, pump impellers." They are also found in more general applications where "erosive abrasion resistance is required."

    Thermal Spray Applications. - Thermal spraying is the process whereby chromium carbide is applied as a coating to some other metal like steel. As with other applications, the high corrosion resistance that results from this bonding is the greatest advantage. In the steel industry, this coating virtually eliminates rusting. Depending on what substance it is mixed with before it is bonded to the steel, it can also act as a barrier against high temperatures of up to 700 to 800 degrees Celsius. For this reason, steel that is thermal sprayed with it is often used in the aerospace industry. Other typical uses are "as coatings for rod mandrels, hot forming dies, hydraulic valves, machine parts, and wear protection of aluminum parts."

    Chrome Plating Alternative - More wear resistant than hard chrome plating, steel that is overlaid with chromium carbide results in a similar surface finish at a much lower price point. In addition, disposal of chrome plated with the overlay is much more environmentally friendly.

    Cutting Tools - Toughness and durability are obvious must - haves when it comes to cutting tools. Chromium carbide improves both of these qualities. Its main advantage as an additive is that it prevents grain growth during sintering (a form of grain refinement), thereby rendering the cutting tool ultra hard.
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Mining Equipment - Prevent Wear With Thermal Spray Coatings

Thermal spray used for mining equipment? You bet! But before you choose a thermal spray coating (also known as 'hardfacing'), you must first understand the type of wear. The answers may surprise you.

Abrasive wear can include lower impact, lower stressed conditions. Here, there will be no fracture, no sudden loss of parent material. Rather, material removal is the result of scratching, filing, a consistent loss in metal at some micro-level. Of course, wear rates will be more dramatic when the mined abrasives are sharp, angular in nature. Proper material hardness, such as an abrasion-resistant steel or ceramic, is key.

Adhesive wear is more of a tearing or material separation between interacting surfaces. It begins with rubbing, and ends with phenomena known as scoring, galling, or seizure. Their occurrence is typically associated with like materials and structure, under an applied load, without lubrication. Here, material choices should consider attributes like ductility, for impact strength. These "softer" alloys available can actually work harden with impact or deformation. The result is increased strength and resistance to abrasion.

Have you already identified the wear mechanism? Made the proper material selection? Well, now it is time to consider thermal spraying. Hardness is the normal measurement for material choice. Again, keep in mind that, under abrasive conditions, harder material choices, like tungsten carbide or ceramic coatings are ideal. But for adhesive wear, where impact strength can be crucial to success, softer, more ductile choices are the answer.

Did you know that how (or where) the thermal spray coatings are applied can also slow down rates of wear? Depending on mined material type and shape, the success of a hardface deposit will be in how it is aligned on the surface. Parallel, perpendicular, even coating spacing and overlap can mean the difference between success and failure. Dissimilarity in thermal expansion characteristics between the coating and parent metal is also something to consider.

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