Since its introduction, CRODON Wear Plate has shown outstanding performance in environments with material sticking/hang-up, abrasion, and impact. For optimal performance, it is critical to use the following recommended methods and techniques for installing CRODON Wear Plate.

 Click Here to view the CRODON Wear Plate Installation Techniques and Recommendations Video

I. FIRST RULES OF INSTALLATION

A. Keep the CRODON Wear Surface Facing the Abrasive Environment The CRODON Wear Plate should be installed so that only the CRODON Wear Surface is exposed to the material flow. Exposing the steel substrate will cause the base material to wear underneath the CRODON wear surface and lead to shortened life cycle. Exposing the steel substrate to sticky material will promote material buildup.

B. Install Edges “Fish-Scaled” or Flush “Fish-scaling” of sheets along horizontal edges protects the base steel from exposure to wear and adhesive materials. It also allows more play in fitting sheets to pre-engineered structures. This method is strongly recommended in chute and chute-type applications. Otherwise, fit edges flush to minimize wear at the edges. It may be necessary to grind back the steel at the edge to obtain a flush finish.

C. Keep CRODON Wear Plate Cool When Welding, Cutting, & Forming Heating CRODON wear surface to 750º F (400º C) will anneal and soften it, significantly reducing its resistance to abrasion.

D. Do not weld to the CRODON wear surface. This will overheat and soften the CRODON wear surface, limit its wear resistance, break the bond with the base metal, and often produce an inferior weld

E. Eliminate Recessed Areas For chutes, truck beds, bins, and other bulk material handling conditions, install CRODON so that sharp corners and recessed corners are minimized. The photo to the side shows an example of how CRODON Wear Plate eliminated material carry back in mining truck beds at temperatures of -20°F.

Plasma Cutter

Water-Jet

CRODON® wear plate bent to match curve in a coal spout

II. Sizes and Shapes:

A. Three Options for Sizes

• Order standard dimensions
   
• Order material pre-cut to your custom requirements, or
   
• Cut in the field to match sizes or fitted dimensions. We recommend high definition plasma (cutting from the CRODON wear surface side). This method provides the fastest, least expensive cut with good results. Water–jet and laser are also acceptable. Cut with a laser from the back side.

B. DO NOT flame cut CRODON Wear Plate.

C. Forming

Form CRODON Wear Plate via rolling and press break WITHOUT applying heat. See addendum attachment for details.

D. Join CRODON Wear Plates

Join multiple wear plates via filet welds, base frames or strong backs.
 

III. STUDDING

When possible, studs are recommended over welding for connecting a wear surface to subsurface structural material. There are two suggested studding techniques for CRODON® Wear Plate: Capacitor Discharge Welding and Arc Stud Welding. The appropriate choice varies according to the thickness of the base material and the size of the stud needed.

A. General Rules for Studs

• Studs should always be installed to the side opposite the CRODON wear surface.
• A minimum base metal thickness of 3/16” is recommended for studding.
• Stainless steel studs are recommended with CRODON wear plate. In all cases ths stud and base material should be compatible.
• Mild steel and stainless steel studs require flux for a sound weld. Studs with the flux within or permanently affixed to the stud base are ideal.
• Make sure contact to the base metal is made in at least two opposing locations around the stud. A single contact can result in a weld not covering the entire stud base. Keep cable lengths to a minimum. Excessive lengths can reduce weld current and produce inconsistent welds.
• Use the minimum amperage recommended for a particular stud and base steel.
• Stud diameter - The following maximum stud diameters should be used for the specified base steel thickness:

B. Capacitor Discharge Stud Welding for Studs

• Required for all stud applications where the base metal is less than 3/8” thick or less than 1.5” wide. This method produces the least heat input to the base metal.
• Stud sizes can range from 1/8” - 3/8”. Keep in mind the base steel thickness, stud diameter.
• Caution - capacitor discharge welds are not as strong as Arc stud welds and are not recommended for environments with high impact or significant vibration.

C. Arc Stud Welding for Studs

• Base steel must be at least 1/4” thick and 1.5” wide.
• Recommended for environments with impact or significant vibration.
• Maximum recommended stud diameter is 1/2”. Keep in mind amperage levels recommended above.
• Usually requires a disposable ceramic ferrule around the base and flux in the stud base or a protective (inert) gas shield to obtain a sound weld.

IV. BOLTING

CRODON Wear Plate can be drilled and, if required, counter sunk by Chromium Corporation for headed bolts to attach two pieces. We strongly recommend this service to be provided by the manufacturing services department of Chromium Corporation.

V. WELDING

• DO NOT WELD TO THE CRODON WEAR SURFACE. Welds do not attach well to the CRODON wear surface and welding directly to the surface will soften the surface and compromise its bond with the base steel.
• Avoid designs requiring multiple small pieces welded together.
• Keep the base material and CRODON Wear Plate under 750 F° (400°C). When possible, thicker base steel is recommended to dissipate heat away from the CRODON surface. Use a temperature crayon or a surface pyrometer on the CRODON wear surface to monitor temperature input.2 Use a welding gel, wet sponge or wet rag to dissipate heat if necessary. ®
• MIG weld with 0.035” or smaller diameter flux cored stainless steel wire is the preferred. Mild steel wire has been used effectively though more care must be taken to monitor heat input. MIG welding is the least disruptive welding method and the best method when tacking is not sufficient. For large weld areas, apply a small root weld followed by skip welding in 1 to 2 second pulses. Wait at least till the red glow of the weld has turned black before beginning the second pass on the skip weld.
• When stick welding, 3/33” 308 stainless steel and 1/8” X-Ergon “Impact-A Wear SD” rods are recommended, especially if large areas are to be welded or fillet welds are used to join pieces. Skip weld for 1 to 2 second intervals. Wait till the weld area is completely black before returning to the area to complete un-welded sections. If using mild steel rods, only use tack welds and use rods no more than 1/8” in diameter, smaller if possible. Tack welds should not be more than ½” long spaced at 2” to 4” intervals. See addendum for additional details.
• When creating a fillet weld, leave at least 1/8” base metal without a bevel. It strongly recommended to use a MIG welder per the recommendations above to create fillet welds. A deeper bevel will result in burn-through to the top and overheat the CRODON wear surface.
  
  

  2 Temperature Limits: No discernible effect up to 700 F° (350 C°). Rapid and permanent degradation of wear resistance above 750 F° (400 C°).
  

VI. Welding, Hard Facing Edges & Forming

Introduction:

Welding via MIG and rod is covered in “Installation/Studding/Bolting/Welding Guidelines”. This addendum covers additional recommendations for:

1. Welding CRODON Plus (AR400 steel backing) and CRODON Standard (mild steel backing) Wear Plate
    
2. Protect exposed edges with hard-facing wire.
    
3. Rolling and Press Break Bending of CRODON Plus and CRODON Standard Wear Plate.

These are recommendations based on field experience and bench testing.Individual trial applications by the operators are strongly recommended before applying to finished products.

1. Welding

Previous information discussed the need to control heat input to the CRODON surface. Heating the surface above 750° F will have a significant detrimental impact on the CRODON Surface making it much less abrasive resistant and impairing its bond with the base metal. Heat sinks or welding gel is always advisable.

Skip Welding

As discussed in other locations, care must be taken when joining large sections of CRODON Wear Plate via continuous welds. When large areas must be welded, skip welding is strongly recommended. Weld in 1 to 2 second intervals allowing enough time between pulses for weld color to become black before returning to join weld segments. MIG welding with stainless flux cored wire, 308, 3/33” stainless rod and X-Ergon 1/8” Impact-A-Wear SD rod are recommended for skip welding applications.

Welding Rod:

We generally recommend MIG (wire) welding with .035” stainless steel or mild steel, flux cored wire, keeping amperage at 67 or minimum possible. When this is not an option, we recommend the following rod and procedures.

1. Product:
   308 Stainless Steel Rod
   3/33” Diameter
   
   Procedure:
   175 – 180 amps, reverse polarity (positive electrode), short arc.
   Recommend skip filet weld from the back using multiple passes as needed.
   Heat sink or cooling gel recommended.
    
2. Product:
   Impact-A-Wear SD
   Code 173-4-000
   Diameter: 1/8”
   Manufacturer: X-Ergon
   P. O. Box 152102
   Irving, TX 75015
   (800) 527-9916
   (972) 721-6870 (fax)
   
   Procedure:
   Use minimal Amperage. The manufacturer recommends minimum 90 amps. Reverse polarity (positive electrode), short to no arc, and thin beads, 1/8” to 3/16” wide. Recommend filet weld from the back or skip welding using multiple passes as needed. Heat sink or cooling gel recommended.
   
   Other:
   Per manufacturer, weld surface will work-harden under impact but not recommended by Chromium Corporation as abrasion resistant surface to protect exposed edges. Additional information on X-Ergon Web Page.

2. Edge and Weld Protection of CRODON Wear Plate

When “CRODON Edge Protection” is impractical or base welds need to be protected, a welded hardfacing surface is indicated. Chromium Corporation developed the following procedures below to apply a hard-facing wire and rod with little or no measurable heat induced deterioration of the CRODON surface. Note that neither of these applications are recommended as alternative methods for joining pieces. They are exclusively for protection of exposed edges or base welds.

Via Hard-Facing Wire:

Manufacturer: Postle Industries
P. O. Box 42037
Cleveland, OH 44142
Contact: Chris Postle
(216) 265-9000

Product:
Postle 2829-SPL hard-facing wire, 0.035” diameter
Hardness – 65Rc

Procedure:
Amps – 150 – 170
Volts - 18
Feed Rate – 220 inches per minute
Skip and pulse welding strongly recommended.
Apply with a weave or 1/8” straight bead.
Do not overlap to CRODON surface.
Use heat sink or cooling gel when possible.

Via Hardfacing Rod:

Manufacturer: X-Ergon
P. O. Box 152102
Irving, TX 75015
(800) 527-9916 (972)
721-6870 (fax)

Product:
MAX-ABRADE™ SD
Code 176-1-0250
Diameter: 1/4”

Procedure:
Use minimal Amperage. The manufacturer recommends minimum 80 amps. Chromium testing showed acceptable results with 60 amps. AC or DC current. Can be applied in two passes. Strongly recommend welding in pulses in 1 to 2 second intervals. Heat sink or cooling gel recommended.

Other:
As applied hardness 62 to 64 Rc. Additional information on X-Ergon Web Page.

3. Rolling and Bending of CRODON Standard and CRODON Plus Wear Plate

General Information:
CRODON Standard and Plus Wear Plate can be formed in one direction on the internal or external diameter. CRODON Plus with base steel greater than ¼” thick is not recommended for forming. We do not recommend forming CRODON Premier (AR500 steel backing) at this time.

Because the CRODON wear surface does not stretch, forming on the external diameter will create a fine network of horizontal cracks across the plate opposite the direction of forming. Adhesion is not compromised but the fine crack pattern can allow fine abrasive materials or corrosives to propagate wear under the CRODON surface.

Formed pieces need to be in a generally rectangular shape without cut internal angles. Never try to create a “cupped” shape or bend a section in more than one direction.

Radius
Always form CRODON on a radius, not a sharp angle. Chromium Corporation recommends a bending ratio of 32 to 1 of the formed angle to the thickness of the base steel.

Base Steel Thickness	Minimum Radius
1/8” (11 gauge)	4”
¼”	8”
3/8”	12”
½”	16”

Press Break versus Roll Forming
CRODON Standard can be formed via press break using a mandrel no smaller than 3” in diameter. The bottom form should be larger than the mandrel. CRODON Plus should be formed by rolling only and not subjected to press break forming.