"Overlay" is short for Chromium carbide weld overlay (CCO) plate. A CCO plate is a type of wear-resistant steel plate created by welding a hardfacing alloy—typically rich in chromium carbides—onto a mild steel baseplate.
The result is a composite material that combines a tough backing plate with a highly wear-resistant surface, making it ideal for abrasive environments commonly found in mining and bulk material handling operations.
Traditional open-arc welding often leads to natural stress relief cracks and uneven ridges on the surface, which are considered a byproduct of the process. In contrast, we use a proprietary sub-arc welding technique that allows better control over heat input, cooling rate, and weld bead shape.
This enables us to significantly reduce internal stresses and achieve a smooth, crack-free surface.
No—it’s a critical performance feature. Conventional overlay plates made with open-arc welding often have surface cracks and ridges. Under impact, these cracks can propagate and lead to spalling, resulting in unpredictable wear rates and even premature failure.
Our smooth surface overlay, produced using sub-arc welding, largely eliminates surface cracks, significantly reducing the risk of spalling and ensuring more consistent wear performance, especially in applications where both sliding and impact wear are present.
Overlay plates are selected when severe sliding abrasion is the dominant wear mechanism, and when longer wear life and reduced downtime are critical.
They’re commonly used in chutes, hoppers, transfer points, and other high-wear areas across mining, quarrying, and material handling operations. Compared to Q&T steel, overlays offer significantly extended service life in highly abrasive operating environments.
Yes—overlay plates can be formed to some extent, but with limitations. Formability depends on the plate thickness, curvature radius, and orientation relative to the welding direction. For tight bends or custom shapes, it's important to consult us first to determine the appropriate processing approach and avoid cracking or delamination.
Wear in industrial equipment is usually caused by one or more of the following mechanisms:
Abrasive wear – when hard particles or rough surfaces slide across a material, gradually removing it. This is the most common type in mining and material handling.
Impact wear – occurs when material repeatedly strikes a surface, causing deformation or surface damage over time.
Erosive wear – caused by particles carried by a fluid or gas that strike the surface at an angle, often leading to surface thinning or pitting.
Corrosive wear – the result of chemical reactions, such as oxidation or exposure to aggressive media, which weaken the surface and make it more prone to mechanical wear.
Surface Integrity – Crack-Free Claim
While FuseTech overlays are engineered for a smooth, crack-free finish, the term "crack-free" refers to the significant reduction of stress-relief cracking commonly seen in traditional overlays. Minor or occasional surface cracks may still occur due to the nature of hardfacing materials, but these do not affect the plate’s wear performance or structural integrity in application.
Technical Data – Typical Values
All values provided in technical charts or specification tables are typical values only. These figures represent the most commonly observed performance based on statistical analysis of multiple production runs. They are not guaranteed and should be used as a general guide to material behaviour and product characteristics under standard conditions.
Application Suitability
Product suitability should always be assessed based on the specific wear environment, equipment design, and operational demands. FuseTech recommends consulting with our technical team to ensure optimal product selection and fabrication methods for your application.
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