Wear-Resistant Overlay Materials in Mining Equipment Fabrication

[MikePhua]

The Role of Weld-On Wear Materials in Heavy Equipment Longevity
In mining and aggregate operations, equipment faces relentless abrasion from rock, ore, and debris. Weld-on wear materials—metallic overlays applied to high-friction surfaces—are a proven strategy to extend service life and reduce downtime. These materials are often applied to buckets, chutes, crusher liners, and dozer blades, where conventional steel would erode rapidly under impact and sliding wear.
One such material, known commercially as Kencast, combines tungsten carbide particles with a steel matrix, offering exceptional resistance to gouging and abrasion. Developed by Kennametal, a company with roots dating back to 1938, Kencast has become a staple in industries ranging from mining to forestry. Its modularity and weldability make it ideal for field repairs and custom fabrication.
Terminology Annotation
- Overlay Plate: A steel plate embedded with wear-resistant particles, welded onto equipment surfaces to absorb abrasion.
- Tungsten Carbide: A dense, extremely hard compound used in cutting tools and wear surfaces, second only to diamond in hardness.
- Gouging Wear: A form of mechanical damage caused by sharp particles digging into a surface, common in rock handling.
- Hardfacing: The process of applying a wear-resistant layer to a metal surface using welding techniques.
Application Techniques and Field Performance
Weld-on wear materials are typically installed using MIG or stick welding, depending on the base metal and overlay composition. The plates are cut to shape, preheated if necessary, and stitched into place. In high-impact zones, multiple layers may be used, or the overlay may be combined with structural reinforcement.
Operators report that properly installed Kencast overlays can last 3–5 times longer than standard AR400 steel in high-wear zones. In one coal mine in West Virginia, dragline bucket lips fitted with Kencast showed minimal wear after 18 months of continuous use, compared to quarterly replacements with conventional steel.
A Story from the Quarry
In southern Kentucky, a welder working for a limestone quarry began experimenting with overlay materials on the plant’s primary crusher chute. After sourcing Kencast at a discounted rate through a surplus supplier, he installed panels along the chute’s impact zone. The results were immediate—material flow improved, and the panels showed no signs of gouging after six months. Encouraged, he expanded the use to loader buckets and dozer blades, eventually convincing management to standardize the material across the fleet.
Comparative Materials and Alternatives
While Kencast is well-known, other manufacturers offer similar products:

• Tricon’s Super-C: A chromium carbide overlay plate with high impact resistance
  
• Hardox 600: A wear-resistant steel with high toughness, used in dump bodies and hoppers
  
• Domite: A cast wear product with embedded carbide tiles, often used in fixed plant applications
  

Each material has trade-offs in weldability, cost, and impact resistance. Chromium carbide overlays, for example, offer excellent sliding wear protection but may crack under heavy impact. Tungsten carbide blends are more expensive but outperform in gouging environments.
Installation Tips and Best Practices
To maximize overlay performance:

• Clean base metal thoroughly before welding
  
• Preheat thick sections to reduce thermal shock
  
• Use low-hydrogen electrodes to prevent cracking
  
• Stagger welds to minimize distortion
  
• Avoid over-welding, which can reduce wear material effectiveness
  

For mobile equipment, overlays should be placed only where wear is concentrated to avoid unnecessary weight and balance issues.
Industry Trends and Material Innovation
As of 2025, wear material technology continues to evolve. Manufacturers are experimenting with nano-structured carbides and hybrid composites that offer both abrasion and corrosion resistance. Some overlays now include embedded sensors to monitor wear thickness and predict replacement intervals.
In addition, robotic welding systems are being deployed to install wear plates with precision, reducing labor costs and improving consistency. These systems are especially useful in large-scale mining operations where downtime is measured in thousands of dollars per hour.
Conclusion
Weld-on wear materials like Kencast have reshaped the way heavy equipment is maintained in abrasive environments. By strategically reinforcing high-wear zones, operators can extend component life, reduce maintenance costs, and improve operational uptime. Whether in a coal mine, quarry, or forestry site, the right overlay material—installed with care and expertise—can make the difference between reactive repairs and proactive reliability.