Practical Guide for Cutting, Forming, and Fabricating D-Plate Wear-Resistant Steel
1. General Overview
D-Plate™ is a bimetallic wear-resistant steel plate engineered for extreme industrial environments.
It consists of:
- Base metal: Low-carbon or alloy steel, providing strength, toughness, and formability
- Overlay: Chromium carbide or tungsten carbide layer, applied using POP (Powder Overlay Process)
This structure delivers:
- High hardness
- Excellent abrasion and impact resistance
- Sufficient flexibility for fabrication
Typical applications include:
- Cement plants
- Mining operations
- Steel mills
- Thermal power plants
- Bulk material handling systems
2. Cutting Guidelines
Due to the high chromium and carbon content of the overlay, traditional oxy-fuel cutting is NOT recommended.
✔ Recommended Cutting Methods:
- Plasma Arc Cutting (preferred)
- Carbon Arc Gouging (air-arc)
- Abrasive Saw Cutting
2.1 Plasma Cutting
- Always cut from the overlay side
- Use ≥150A power source (higher current = faster cutting)
- Optimize cutting speed to reduce dross
2.2 Carbon Arc Gouging
Required setup:
- DC power source (≥60–80V)
- Compressed air ≥6 bar
Typical parameters:
| Electrode Ø | Current | Min Air Flow | Optimum Air Flow |
|---|---|---|---|
| ≤ 6.3 mm | 250–400 A | 100 L/min @ 3 bar | 300 L/min @ 6 bar |
| ≥ 9.5 mm | 350–600 A | 200 L/min @ 6 bar | 500 L/min @ 6 bar |
Cut from the carbon steel side
Remove burrs using a grinder
2.3 Abrasive Saw Cutting
- Use silicon carbide blades
- Suitable for thin plates and straight cuts
3. Forming and Bending
3.1 Cold Forming
- Plates can be rolled into cones or cylindrical shapes
- Always roll along weld bead direction
Key rule:
Do NOT exceed minimum bending radius to avoid cracking
| Overlay Thickness | Base Thickness | Concave Min Ø | Convex Min Ø |
|---|---|---|---|
| 3–6 mm | 9.5 mm | 400 mm | 250 mm |
| 8–12 mm | 12.5 mm | 450 mm | 400 mm |
Important:
- Concave bending (overlay inside) is preferred → reduces cracking
- Use 12 mm carbon steel liners on rollers to avoid surface damage
3.2 Hot Forming
For plates >20 mm thickness:
- Use local or furnace heating
- Max temperature: 650°C (1200°F)
- Max holding time: 1 hour
For special alloys → consult BCC technical support
4. Welding & Joining Methods
4.1 General Rules
- Always weld on the base metal side
- Do NOT weld on overlay surface
- Stop weld ≥3 mm below overlay transition line
- Clean and grind edges before welding
4.2 Welding Processes
Accepted methods:
- SMAW (Stick welding)
- GMAW (MIG/MAG)
- FCAW (Flux-cored arc welding)
Typical Consumables
| Material | Standard | Classification |
|---|---|---|
| Carbon steel | AWS A5.1 | E7016 / E7018 |
| Solid wire | AWS A5.18 | ER70S-3 / ER70S-6 |
| Flux-cored wire | AWS A5.20 | E70T-1 / E71T-1 |
| Stainless transition | AWS A5.4 | E309 |
When in doubt:
Use E309 stainless filler to prevent dilution and cracking
5. Attachment Techniques
5.1 Fillet Welding
- Most common method
- Weld only on base metal
- Keep weld root ≥3 mm below overlay
5.2 Plug Welding
- Hole diameter: ≥25 mm
- Spacing: 300–600 mm
Process:
- Weld from base side
- Cap with hardfacing (e.g., D100)
5.3 Stud Welding
- Carbon steel studs ≥19 mm
- Larger studs → use SMAW (E7018)
5.4 Countersunk Studs
- Cut from overlay side
- Head depth: ~4 mm below surface
- Seal with hardfacing
6. Butt Welding
Two options:
✔ Partial Penetration
- Leave 2–3 mm gap from overlay edge
✔ Full Penetration
- Grind back overlay ≥6 mm
Use:
- E7018 (low hydrogen)
- or E309 (stainless)
7. Machining & Finishing
- Grind edges and holes smooth
- Remove slag and burrs
- Cap exposed joints with hardfacing
Avoid overheating:
to prevent metallurgical softening
8. Key Best Practices (Quick Summary)
✔ Cut from overlay side using plasma
✔ Roll along weld direction
✔ Weld only on base metal
✔ Maintain 3 mm clearance from overlay
✔ Use stainless filler when unsure
✔ Protect all joints with hardfacing
Conclusion
D-Plate™ is not just a wear plate — it is an engineered system combining:
- Advanced material design (POP technology)
- Practical fabrication flexibility
- Proven field performance
