(Practical Guide for Cutting, Forming, and Fabricating D-Plate Wear-Resistant Steel)
1. General Overview
D-Plate™ is a two-layer wear-resistant steel plate, consisting of:
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Base metal: low-carbon or alloy steel for strength and formability.
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Overlay: chromium or tungsten carbide alloy applied by POP (Powder Overlay Process) welding.
This combination provides high hardness, excellent wear and impact resistance, and sufficient flexibility for shaping and fabrication.
Applications: cement, mining, steel, thermal power, and other heavy industries exposed to abrasion, impact, or corrosion.
2. Cutting Guidelines
2.1 Recommended Methods
Due to the high Cr and C content in the overlay, traditional oxy-fuel cutting is not suitable.
Use one of the following:
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Plasma Arc Cutting (recommended)
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Carbon Arc Gouging (air-arc)
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Abrasive Saw Cutting
Plasma Cutting
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Cut from the overlay side to ensure a clean cut and minimal burr.
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Use 150A or higher power sources. Higher current → faster cut.
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Adjust cutting speed to reduce dross formation.
Carbon Arc Gouging
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Required setup: DC power source (min 60–80 V) + compressed air (min 6 bar).
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Typical parameters:
Electrode Ø Current Air Flow (min) Air Flow (optimum) ≤ 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.
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Remove burrs with a grinder after cutting.
Abrasive Saw Cutting
Use a silicon carbide blade (similar to concrete cutting) for straight cuts on thin plates.
3. Forming and Bending
3.1 Cold Forming
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Most D-Plate grades can be cold rolled into cones or cylindrical segments.
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Always roll in the direction of weld beads.
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Avoid exceeding the minimum bending radius to prevent 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 |
Concave bending (overlay inside) compresses the hard layer → reduces cracking.
Use protective carbon-steel liners (12 mm thick) on top rolls to prevent scratching or indentation.
3.2 Hot Forming
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For plates thicker than 20 mm, use local or furnace heating.
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Max temperature: 650°C (1200°F), Max time: 1 hour.
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For special alloys, consult BCC technical support.
4. Welding & Joining Methods
4.1 General Rules
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Always weld on the base metal side.
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Do not weld over the overlay surface.
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Stop welds 3 mm below the transition line between base and overlay.
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Clean and grind edges before welding.
4.2 Welding Processes
Acceptable methods:
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SMAW (Shielded Metal Arc Welding)
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GMAW (MIG/MAG)
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FCAW (Flux-Cored Arc Welding)
Typical Electrodes/Wires:
| Material Type | 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 (for dissimilar joints) |
When unsure, use stainless filler (E309) to avoid contamination or embrittlement.
5. Attachment Techniques
5.1 Fillet Welding
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Easiest and most common method.
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Weld only on base metal, not on the overlay.
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Keep fillet root 3 mm below overlay transition.
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Reinforce using carbon steel angle if necessary.
5.2 Plug Welding
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Drill or plasma cut holes Ø ≥ 25 mm, spacing 300–600 mm.
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Weld through holes from base side, then cap with hardfacing wire (e.g., D100).
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Ensure 3 mm clearance below overlay.
5.3 Stud Welding
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Carbon-steel studs Ø ≥ 19 mm can be directly welded on the base.
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For larger studs, use SMAW with E7018.
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Ensure proper spacing for load distribution.
5.4 Countersunk Studs
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Cut holes from overlay side using orbital plasma torch or machining.
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Fit countersunk heads ~4 mm below surface.
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Seal using hardfacing overlay.
6. Butt Welding
Two options:
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Partial Penetration: Leave 2–3 mm gap from overlay edge.
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Full Penetration: Grind back overlay at least 6 mm.
Use standard low-hydrogen electrodes (E7018) or stainless (E309).
7. Machining & Final Treatment
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Grind edges and holes smooth to remove slag or burrs.
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Cap exposed joints or plug welds with hardfacing overlay for wear protection.
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Avoid overheating to prevent metallurgical softening.
8. Summary of Key Practices
✅ Cut from overlay side using plasma arc.
✅ Roll along weld direction, use protective liners.
✅ Weld only on base metal, 3 mm below overlay transition.
✅ Use stainless filler when unsure.
✅ Cap all joints on overlay side with hardfacing.
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