Flatness Issues in CCO Plates: Causes & Fixes

For customers who attempt to process composite wear-resistant steel plates on their own, plate flatness becomes a critical factor. Whether during storage, transportation, or cutting, any warping or unevenness in the plate can lead to serious production challenges. Poor flatness affects not only cutting precision but also fit-up accuracy, welding consistency, and downstream fabrication.

I.Why Flatness Matters in Chromium Carbide Overlay Wear Plates

Flatness directly impacts how a wear plate performs during secondary processing. A plate that is not flat can cause:

Misalignment in assembly

Uneven or inaccurate cutting

In applications where precision is key—such as screen plates, liners, or transfer chutes—even a few millimeters of warping can make a significant difference.

II.What Causes Flatness Issues in Bimetallic Wear Plates?

The key lies in the structure of the chromium carbide overlay wear plate itself. This dual-layer construction, though extremely effective for wear resistance, introduces challenges during manufacturing:

The welding overlay process involves high heat input followed by rapid cooling.

This leads to internal stress due to uneven thermal expansion and contraction.

Since the hardfacing and base metal have different thermal properties, residual stress builds up.

While manufacturers strive to balance these stresses, they cannot be completely eliminated.

III.Plate Orientation: Does It Matter Which Side Faces Up?

Absolutely. Orientation plays a key role in cutting:

In many customer cases, when cutting from the base steel toward the hardfacing layer—especially with non-laser cutting methods and lower-powered machines—the final segment of the cut often lacks sufficient power and precision, resulting in uneven or incomplete cuts.

IV.Why Laser Cutting Is Preferred for CCO Plates

Laser cutting provides better control over thermal input and distortion. Here’s why it stands out for chromium carbide wear resistant plates:

（1）Minimal heat distortion means less stress is introduced during the cutting process.

（2）Cuts are cleaner, with reduced spatter and better edge quality.

（3）For bimetallic wear plate liners, precise cutting is critical to ensure correct fitment.

（4）When laser cutting is not an option, customers should ensure:

（5）Cutting starts from the hardfacing side

（6）Preheating may be needed to minimize cracking

（7）Avoid dragging or bending the plate during setup