Large-particle cladding is a special cladding process that refers to adding large-size wear-resistant alloy particles (such as tungsten carbide, chromium alloy, molybdenum alloy, etc.) to the molten pool during the welding process, so as to make them uniformly distributed in the weld channel, thus enhancing the wear resistance, impact resistance and corrosion resistance of the cladding layer. This process is mainly used in industrial equipment that requires high wear resistance, such as mining machinery, construction machinery, metallurgical equipment, etc.
Why choose Large Particle Surfacing?
• Excellent wear resistance: the high hardness of the alloy particles significantly increases the wear life of the part.
• Strong impact resistance: large particles are evenly distributed to improve the material's resistance to impact and cracking.
• Strong bonding: the molten particles form a strong bond with the substrate and are not easy to flake or break.
• High temperature resistance: suitable for high temperature wear environment, such as metallurgy, mining, petrochemical industry.
• Repairability: suitable for repairing and remanufacturing of wear parts, reducing costs.
About the process/method of large particle cladding
1. Open Arc Welding (Open Arc Welding)
Adopting open arc welding method, the molten pool is deeper, which is suitable for the deposition of large particle alloy.
Suitable for large area wear-resistant surfacing, such as mine conveyor pipe, crusher liner, etc..
2. Plasma Surfacing (PTA, Plasma Transferred Arc)
Adopting plasma arc as heat source, high temperature, concentrated energy, good combination of welding layer and base material.
Suitable for high precision, high wear-resistant parts, such as drilling tools, molds and so on.
3. Submerged Arc Welding (SAW)
Suitable for thick layer surfacing, high welding efficiency, suitable for steel plates, roller conveyor and other large area workpieces.
4. Laser Cladding
Small heating area, small workpiece deformation, suitable for high requirements of the workpiece, such as aircraft engine parts.
Conventional cladding VS. Large particle cladding
In terms of the size of the alloy particles conventional conventional cladding tends to choose 0.1-0.5mm fine particles, while large particle cladding chooses 1-5mm large particles. In terms of abrasion resistance, conventional cladding has very ordinary abrasion resistance due to the selection of fine particles, while large particles have high abrasion resistance. In terms of impact resistance, traditional cladding is prone to spalling and cracking. Therefore, the service life is shorter and needs to be replaced frequently. Large particle cladding should have a uniform distribution of particles, forming a “particle-enhanced structure” inside the cladding layer, which makes the wear homogenized and the service life of the workpiece longer. Compared with traditional cladding, the thickness of large particle cladding can be up to 3-10mm, which is more durable than ordinary wear-resistant layer.
Common Large Particle Surfacing Materials
• Tungsten Carbide (WC)
Extremely hard (HRC 70-80), almost one of the hardest wear-resistant materials in industry.
Suitable for extreme wear environments, e.g. crusher hammers, digging bucket teeth, etc.
• Chrome (Cr)
Mainly used in corrosion + wear resistant environments, such as mining machinery, conveying equipment, etc.
Higher hardness (HRC 55-65), high wear resistance.
• Molybdenum alloy (Mo)
Provides high temperature wear resistance, suitable for high temperature furnace linings, heat resistant pipes, etc.
Hardness in HRC 50-60, suitable for high temperature wear conditions.
• Composite Ceramic Particles
Combines the advantages of metal and ceramic to provide superb wear resistance and impact resistance.
Suitable for construction machinery, bulldozer track plates, concrete mixer blades, etc.
Main application areas
- Mining machinery: crusher hammer head, conveyor liner, excavator bucket edge, etc. Metallurgical equipment: steel mill rolls, sintering machine grate plate, continuous casting machine, etc.
- Metallurgical equipment: steel mill rolls, sintering machine grate plate, continuous casting machine and so on.
- Petrochemical industry: drill bits, mud pump bushings, wear-resistant pipes, etc.
- Construction machinery: bulldozer track plate, concrete mixer blades, etc.
Where is Large Particle Surfacing applicable?
Large particle surfacing is the best choice if your equipment faces the following problems!
- Equipment operating in high wear environments (e.g. crushers, conveyors, mixing equipment)
- Equipment is subjected to frequent shock loads (e.g. construction machinery buckets, track plates)
- Equipment operating in high temperature or corrosive environments (e.g. high temperature furnace linings, oil drilling tools)
- High maintenance costs and the need to extend equipment life.
Through the above content we understand that large particle surfacing is a highly efficient surface strengthening technology, through the addition of high hardness large particle material in the molten pool, to improve the wear resistance and service life of the workpiece. It is widely used in mining, metallurgy, petrochemical and construction machinery and other fields, for heavy-duty working conditions equipment to provide reliable wear protection. Want to know more about large particle surfacing? Contact us.
Post time: Mar-19-2025