Ultraclad 800 Total Carbide Saturation Special Steel Overlay Plate – 40 Times the Life of Mild Steel

The UltraClad 800 TCS Range

Our new overlay system, incorporating state of the art electronic technology, has enabled us to produce and overlay with Total Carbide Saturation.

This process provides maximum wear resistance for your money!

From the photo micrograph you will see that the new Ultraclad 800 TCS is jam packed with wear resistant carbides, for maximum performance and wear resistance.

If you use overlay plate, why not get the best value for your money and buy Hoverdale Ultraclad TCS. Call or e-mail us today to find out more!

The products in the range are:

  • Ultraclad 801 – general purpose overlay plate
  • Ultraclad S801 – stainless steel backing plate for high temperature applications up to 450 degrees Celsius
  • Ultraclad 802 – complex carbide for maximum abrasion resistance at high temperatures of up to 650 degrees Celsius
  • Ultraclad S802 – stainless steel backing plate
  • Ultraclad 803  – corrosion-resistant
  • Ultraclad S803 – stainless steel backing plate

What makes Ultraclad Different?

What you get when you choose Ultraclad is:

  • 40 – 50 times the wear resistance of mild steel
  • An in-house test certificate if required
  • Ex-stock delivery
  • A custom-made component service
  • Products manufactured in the UK to ISO 9001 standards

Frequently Asked Questions

What is Ultraclad 800 overlay plate?

Ultraclad overlay plate consists of a plate of plain steel which has been fusion-bonded with a composite of chromium iron carbon alloy and chromium carbides for the purpose of resisting severe abrasion. The metal layer is made up of about 40% chromium carbides.

The hardness of the metal deposit cannot be  shown properly in terms of Brinell, Rockwell or Shore readings because it consists of a very large number of extremely hard particles in a comparatively soft matrix, rather similar to a diamond grinding wheel. The hardness of the particles themselves is equivalent to about 1750 on the Brinell scale and that of the matrix about 450. The result of the hardness test will be somewhere between these depending upon the type of penetrator used and where it lands.

The overlay layer has a true metallurgical bond with the base plate (as in welding) and will not separate. If the stress is so sever as to cause the destruction of the plate, metal will be torn loose from the base plate below the clad layer.

There are hundreds of fine cracks in every square foot of the hard layer and these cracks are both necessary and desirable. In all metals and metal carbides the harder and more abrasion-resistant the material is, the more brittle it is. For this reason, the hard carbide content of castings must be held at a low level or the part would break into small pieces on cooling in the mould. In wrought materials this level must still be lower to allow working of the material in rolling.

The unique construction of Ultraclad 800 overlay plate allows the use of very hard carbide material in high concentration by fusing the hard layer to a ductile plate and allowing it to crack vertically at random. The cracks are so numerous (more than one per inch) and the shrinkage stress in the root of each is of such low magnitude that there is no progression into the base metal. The plate may thus be bent and formatted without damage.

Is Ultraclad 500 overlay plate better than plate with conventional hardfacing?

Yes, at least three times better. There are two principal reasons. Firstly, a deposit by conventional facing cannot have the high analysis available in Ultraclad 800 overlay plate because enough carbide material cannot be packed in the tube of a conventional welding electrode or wire.

Secondly, the conventional facing process will melt base metal up to 50% or more so that the final deposit analysis is greatly diluted from that of the material applied. Ultraclad 800 overlay plate, therefore, has many more abrasion resistant carbides per square inch of surface than a conventionally applied facing.

What is the abrasion resistance of Ultraclad 800 overlay plate?

Tests made by a major Research Institute (available for inspection) show a cold abrasion ratio of 30-1 over mild steel and 12-1 over heat treated alloy. Tests in hot abrasion have been made by various oil companies. One test has involved about 300 materials over a ten year period. The material of Ultraclad 800 overlay plate gave an abrasion ratio of 20.2 to 1 over mild steel at 565 degrees Celsius. In such hot tests it has exceeded all commercially feasible material available. Tests in service in an iron ore chute gave 21-1 superiority over hard wearing resistant steel.

What is the impact resistance of Ultraclad 800 overlay plate?

Two types of impact must be considered. The first involves the entire plate and is a measure of its stiffness and toughness. Toughness is about that of mild steel plate with much greater stiffness toward deformation when struck by a falling heavy body.

The second type of impact involves the hard layer only and depends on the velocity of the particles striking the hard layer. When a hard particle strikes the overlay at angles below 70 degrees to the normal, at a velocity in excess of about 40 feet per second the brittle carbide may be shattered and the hard layer will erode. It is not recommended for use in such velocities where the abrading material is very hard and its particle size considerable.

How is Ultraclad 800 overlay plate cut?

Ultraclad 800 overlay plate may be cut with plasma cutting equipment in the same manner as carbon steel. IT may also be cut by first removing the overlay with a carbon and air arc (or air arc) then cutting the steel backing plate with a conventional oxygen torch. Ultraclad 800 overlay plate may be sawn from the carbon steel side down to the hard layer, after which it can be broken off.

Can Ultraclad 800 overlay plate be cold formed?

Ultraclad 800 overlay plate may be formed or rolled cold to a radius not less than about 20 times the thickness of the plate, forming with or against the clad layer. If sharper bends are needed, the plate may be heated to any convenient forming temperature, say 820 degrees Celcius and formed as desired.

Can Ultraclad 800 overlay plate be welded?

Ultraclad 800 overlay plate can be welded in place with any carbon steel electrode of the commonest type by welding on the steel backing. No preheating or special precautions are necessary.

How We Can Add Value

There are a number of ways in which we can offer value through our industry-leading Ultraclad, our experience and our abilities to fabricate and custom-make hard metals. We offer value in a number of ways:

  • We have the technique and equipment to machine hard metals to any customer specifications
  • We can fabricate products in hard metals as well as strategically reinforcing target areas in material transfer systems to provide a long life at a relatively low cost
  • We can grind these products to user-defined dimensions
  • We offer a range of products (Ultraclad, RQ&T plate & Wearalloy 400, 450 and 500 BHN) to ensure that we have the right solution to each problem
  • We can offer stainless steel cladding, Inconel cladding & can make overlay to order to any customer requirements
  • We can make overlay to customer-defined specifications – customers can give us their requirements and we can custom-design hard metals to do the job. To our knowledge, we are the only company that can do this
  • We have a 10-tonne overhead crane and so we can fabricate up to 10 tonnes

Can We Help?

We would like to offer you a free site survey with a report and recommendations. We offer a pro rata payment plan where if you accept our recommendation you only pay the full price when we achieve our promised results.

We can work with you to achieve the planned maintenance program by making components last longer by the strategic use of hard metals/ceramics.

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