TriBraze
TriBraze is a quenched and tempered, thru-hardened, high impact, superior abrasion resistant alloy steel with very low sulfur content (less than 0.003%).
It is specially treated for sulfide shape control which improves internal cleanliness, notch toughness, torching and formability characteristics, and weldability.
The engineered balance of alloying elements provide maximum strength and ductility while the controlled heat treating and extremely low sulfur develop an ideal hardness/toughness ratio.
Advantages & Features
Applications
Chemical Composition
Engineering Data
Microstructure
Machining TriBraze
Cold Forming TriBraze
Cutting TriBraze
Welding TriBraze
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Advantages & Features
Balanced alloy steel chemistry for optimum hardness/toughness ratio.
High hardness for better wear resistance (through-hardened).
High impact resistance.
Excellent hardenability for depth of hardness.
Provides longer service life and less downtime to lower your overall maintenance cost.
Fine grain structure.
Extremely low sulfur content & sulfide shape control.
Tempered martensitic microstructure with titanium carbo-nitride particles to improve resistance to wear.
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Applications
A partial list of typical TriBraze applications:
Bark Hammers
Bins & Hoppers
Blades
Blast Furnace Handling Equipment
Blow Tank Target Plates
Buckets & Components
Bucket Lips
Chipper Hoods & Components
Chip Solo Components
Chutes
Conveyors & Liners
Crusher Components
Cyclones
Debarking Drum Components
Drums & Sprockets
Dust Collector Systems
Fan Blades & Housings
Flatback Elbows
Flights
Flume Liners
Hammers
Hammer Mill Side Plates
Heel Plates
Hooks
Hot & Cold Strip Mill Guides
Impact Ladders
Jack Ladder Components
Kickout Arms
Lift Forks
Liner Plates
Log Decks
Mine Cars & Equipment
Pins
Pipe Mill Easy Down Assemblies
Sand Systems
Scrap Handling Equipment
Scraper Blades
Screens
Shakeout Machines
Shot Blast Equipment
Skip Cars
Speed-up Rolls
Sprockets
Truck Body Liners
Washers
Wear Plates
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Chemical Composition
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Carbon
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0.18 / 0.24
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Manganese
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0.78 / 1.00
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Phosphorous
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0.025 max
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Sulfur
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0.003 max
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Silicon
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0.20 / 0.40
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Chromium
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1.60 / 1.80
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Nickel
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0.50 / 0.85
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Molybdenum
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0.20 / 0.30
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Titanium
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0.01 / 0.10
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Boron
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.001 min
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Aluminum
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.015 min
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The specially designed Carboncontent allows TriBraze to be heat treated to a high hardness while still remaining readily weldable.
The Manganese content enhances the hardness and hardenability of the steel while promoting the ductility.
The very low Phosphorous and Sulfur content make for a very clean steel and greatly enhance the toughness. Because Tri-Braze is specially treated for sulfide shape control, any sulfide or oxide inclusions inherent in the steel will be limited, microscopically small, and globular in shape. This in turn means a more homogeneous material with more uniform properties in the longitudinal, transverse and thru-thickness directions.
The Silicon content provides adequate deoxidation and assures a fully killed steel.
Chromium and Molybdenum promote hardenability (the depth of hardness), enhance the atmospheric corrosion resistance, and increase high temperature properties.
The Nickel addition adds to the strength and toughness but is used sparingly in order to reduce the difficulties of rolled in scale thereby producing a smoother plate surface.
Titanium benefits the Boron by combining with nitrogen, allowing the Boron addition to be effective. Boron is used to intensify the hardenability. A very small amount of Boron is required for a marked increase in the hardenability. Boron treated steels generally possess better hot and cold working characteristics than other alloy steels having equal or higher hardenability.
It also promotes grain refinement, imparts temper resistance, and forms a very hard complex Titanium Carbo-Nitride for better wear resistance. The Aluminumacts as a deoxidizer and for control of inherent grain size.
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Engineering Data
Hardenability: TriBraze possesses excellent hardenability for depth of hardness.
Tensile Strength & Hardness:
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Brinell Hardness*
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418/ 512 BHN
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|
Yield Strength
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192,000 / 240,000 psi
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|
Tensile Strength
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215,000 / 267,000 psi
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Elongation
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12/20 %
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Reduction of Area
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40/60 %
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Although 418 BHN is the minimum hardness obtained with Tri-Braze, 444 BHN is the target hardness level and most plates will be 444 BHN minimum.
Elevated Temperature Strength:
TriBrazeis a quenched and tempered steel. While all steels tend to lose strength when used at elevated temperatures, creep, stress-rupture and elevated temperature tests have shown that TriBraze maintains good strength at temperatures approaching 1000 °F. Because TriBraze is tempered at 400 °F, heating it above this temperature will cause a decrease in hardness and strength but the lowering of these properties will be very gradual.
Modulus of Elasticity:
The typical variation in the modulus of elasticity for TriBraze from room temperature to 1000 °F is shown below:
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Test Temp
|
Tension
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Compression
|
|
°F
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(PSI)
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(PSI)
|
|
Room Temp
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29,500,000
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30,860,000
|
|
200
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28,320,000
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29,625,000
|
|
400
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26,550,000
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27,774,000
|
|
600
|
24,780,000
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25,922,000
|
|
800
|
23,010,000
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24,070,000
|
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1000
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21,240,000>
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22,219,200
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Coefficient of Thermal Expansion:
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Inches/Inch/°F
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Temperature Range
|
|
6.6 x 10-6
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70°F to 400°F
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|
7.3 x 10-6
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10°F to 1200°F
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Atmospheric Corrosion Resistance:
Minimum of 6 times that of carbon steels.
Shear Strength:
65% to 75% of the tensile strength--approximately 148,000/172,000 psi.
Impact (Toughness / Ductility):
Typical thru 3/4" thick Absorbed Energy (Ft.- Lbs.)
|
Test
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Grain Direction
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Grain Direction
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|
Temperature
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Longitudinal
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Transverse
|
|
Room Temp
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<50 / 72
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40 / 50
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32°F
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45 /66
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35 /40
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|
0°F
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35 /60
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25 /36
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-40°F
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25 /50
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20 /35
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For maximum Service Life and flexibility of application, an alloy plate product must offer an ideal ratio of toughness / hardness yet remain a satisfactory degree of formability and ease of field welding.
TriBraze is produced by carefully controlled heat treated processes to provide the requirements of this ratio demand.
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Microstructure
The microstructure of TriBraze consists mainly of tempered martensite.
An etched photomicrograph shows the presence of the Titanium Carbo-Nitrides. These small Titanium Carbo-Nitrides are randomly dispersed throughout the martensitic matrix and are extremely hard and improve the abrasion resistance of the steel.
Due to the virtual elimination of most nonmetallic inclusions, the initiation sites for crack propagation along the torched edge and/or in the heat affected zone, are also eliminated. This in turn enhances the torching characteristics and the weldability of Tri-Braze, due to the virtual elimination of most non-metallic inclusions, the initiation sites for crack propagation along the torched edge, and/or in the heat affected zone, are also eliminated.
Each heat of TriBraze is specially processed using state-of-the-art desulfurizing techniques to obtain very low sulfur contents and to achieve "sulfide shape control". Through this process any sulfide inclusions remaining in the steel are modified so that they resist deformation during hot working and remain virtually globular or spherical in nature.
In this form, inclusions have much less effect on the steel's ductility and the directional characteristics are substantially reduced. The elimination of sulfide stringers removes a source of commonly known weak points at which many types of steel failures originate.
Through this special processing, TriBraze has enhanced quality and greatly improved properties. Some of the benefits are noted below:
1. Internal Cleanliness:The internal cleanliness is greatly improved through virtual elimination of most inclusions. Tri-Braze will meet the most restrictive ASTM Ultrasonic Testing Specification (ASTM A578-82 Level 1) for internal cleanliness.
2. Notch Toughness:Charpy V-Notch impact values are higher than when conventional processing practices are used. While both the longitudinal and transverse impact energies are higher, it is the transverse values which show the greatest improvement. The transverse energy levels approach those in the longitudinal direction of a non-desulferized heat.
3. Formability: In conventionally processed steels a much larger minimum bend radii is needed when the bend axis is parallel to the plate length (transverse bend) than when the bend axis is perpendicular to the plate length (longitudinal bend). In many cases, these so called "hard way" bends were avoided due to possible breakage. Through sulfide shape control processing' "hard way" bends are no longer the hard way. Bends can be made in either direction with equal ease. As a general rule, minimum bend radii recommended for longitudinal bends in conventionally treated steels can be used for transverse bends in desulfurized steels.
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Machining TriBraze
For Drilling TriBraze
• Machine, work set-up and tooling should be as rigid as possible.
• Tooling should be cobalt or carbide and kept sharp
• Drills with short shanks are preferred for torsional stiffness
• Tooling should be flooded with a good grade of coolant.
• Satisfactory drilling results have been obtained using:
o A split point drill with an included tip angle of 150° and an edge clearance of 6°
o Feed rate of .001” / .004” per revolution for drills 1/8” thru 1”; and .004” / .010” per revolution for drills 1-1/32” and larger.
o Speeds of 10 / 20 SFPM.
For Tapping Holes in TriBraze:
• Layout all hole locations on the TriBraze plate
• Prior to drilling the pilot hole, use an oxy-fuel torch to heat the location, achieving an orange glow in the TriBraze. This slightly anneals the steel in this location, allowing the holes to be tapped. Because the hole will have a fastener, does not alter the performance of the TriBraze. Repeat for each hole to be tapped.
• Drill pilot hole after it has cooled to less than 100° F
• We have found the best success tapping TriBraze using Greenfield brand taps.
For Turning & Milling TriBraze
• Use C-5 or C-6 Carbide
• 50/100 SFPM
• .001” / .003” Chip Load
• Flood with a good grade of coolant.
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Cold Forming TriBraze
Moderate forming can be satisfactorily performed in all thicknesses, provided adequate power is available and proper procedures are used.
Generally, the power required to form TriBraze will be approximately 4 times that required for carbon steel, or 40% more than forming AR 400.
The following will assist you in cold forming TriBraze
Flame cut and rough edges should be snagged with a grinder in the bend area.
Use the largest radii permissible. (8 times the plate thickness is generally the minimum radius with bend lines perpendicular to final rolling direction of plate.)
If bend lines must be parallel to the final rolling direction (grain direction), the bend radius must increased (each TriBraze plate is marked with the grain direction).
Spring-back allowances must be considered and will depend on plate thickness and severity of the bend.
For the purpose of estimating forming equipment required to form TriBraze, the tensile strength may be estimated by multiplying the BHN value by 500.
Lower hardness TriBraze can be furnished for more severe forming requirements with a slight decrease in wear resistant properties
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Cutting TriBraze
Flame cutting is the recommended method for shape cutting, piercing large holes and beveling TriBraze. Conventional flame cutting procedures and fuels are satisfactory.
Some hardening of the cut edges may result when the heated cut surface is drastically quenched by the larger mass of surrounding cold base metal. If machining is required on torch cut material, either allow sufficient stock removal to get below the hardened edge or preheat to approximately 400°F prior to flame cutting.
As an added precaution, plates stored below 50°F, and plates in excess of 1-1/2" in thickness should be preheated to approximately 200°F.
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Welding TriBraze
The first consideration for welding TriBraze is the correct welding alloy. Unlike welding AR400 or AR500, which specify 7018 for welding, TriBraze has a higher concentration of chromium, nickel and molybdenum. Standard 7018 does not contain enough alloy to work with this true alloy steel.
We recommend welding TriBraze with TriWeld 3 stick or TriWeld-FCG wire to assure successful welds.
The amount of heat introduced into the weld can have drastic effects on the joint strength and wear plate hardness.
Large heat inputs result in wide heat affected zones that are low in hardness and impact properties. Narrow heat affected zones are kept low by using small beads and multiple passes.
Stringer passes should be made on alternating sides to help control distortion. Weave beads should avoided. If it is absolutely necessary to use weave beads, the deposit width should be limited to three (3) times the electrode diameter or five (5) times the diameter for wire.
The final weld passes should be uniform in shape and contour. The beads should taper smoothly into the base plate, undercutting should not be allowed.
Any and all visible weld imperfections should be removed before successive weld passes are made.
Post Weld:
The completed weldment should be allowed to slow cool to ambient temperature.
Post weld thermal treatment is generally not necessary, but is suggested when the welded component is subject to extreme load conditions. When deemed necessary, the welded component can be stress relieved by heating to 400°F and holding for one-half to one hour per inch of thickness of the plate. The cooling should be done in still air.
Post Weld Inspection - rough, irregular shaped welds should be ground smooth to remove stress risers that could be sites for crack initiation. Ensure freedom from cracks, gouges, laps, undercut or other imperfections. Visual examination, preferably 48-72 hours after welding, should be made to ensure freedom from cracks, gouges, laps, undercuts or other imperfections.
Avoid these pitfalls when welding TriBraze:
1. Hydrogen Cracking
Whenever high strength steels are welded, there is always a danger of cracking due to the presence of moisture. Care should be taken to assure that electrodes and base metal surface are free from moisture. To avoid under-bead cracking, the hydrogen content of the weld should be kept to a minimum.
Common sources of hydrogen are: (a) water and heavy rust on plate; (b) manual shielding arc electrode cuttings; (c) submerged arc welding flux that has been improperly stored; (d) contamination on surface of coiled electrode core wires.
» If hydrogen embrittlement is suspect, it is always good practice to heat soak the completed weld at 250°F, per hour per inch of thickness.
2. Undercutting
Undercutting is simply a joint that has not been properly filled. The base material is melted, mixed with the filler metal and solidified as a weld bead. It is usually characterized by high crown.
Undercutting is probably the most common of all welding defects. There are many causes but the most common is excess travel speed...quite simply, there is not enough weld metal to fill the joint.
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Super-C
Super-C is a composite plate consisting of a low carbon steel base plate and an alloyed wear resistant cladding. The unique Kennametal Tricon cladding process produces a plate with a surface that is harder, tougher, and more wear resistant than plate obtained by any other process. The low carbon steel base plate enables the plate to be welded, bolted or studded to existing structures, while the cladding provides a premier wear surface capable of working in the most hostile environments. Super-C can be successfully applied in applications involving severe abrasion and moderate impact.
Super-C cladding gets it's superior wear properties through careful metallurgical and process control. Maximum carbide concentration and optimum carbide alignment are achieved through a proprietary process and unique alloying, making Super-C superior to any other wear resistant plate available on the market.
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Advantages & Features
Applications
Chemical Composition
Microstructure
Welding Super-C
Cold Forming Super-C
Cutting Super-C
Advantages / Features
Consistent hardness
Formable
Various thicknesses available
Controlled chemistry
Austenitic matrix with hard carbides
Small heat affected zone
High concentration of carbides
Controlled carbide alignment
Easily welded to most structural surfaces with Prime Arc electrodes.
Good impact resistance
Excellent abrasion resistance
Excellent heat resistance
Good corrosion resistance
Longer service life
Less downtime
Low overall maintenance costs.
Complete inventories maintained for prompt service.
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Super-C Applications
Below is a partial list of typical applications for Super-C.
Flatback Elbows
Crusher Mill Liner Plates
Grizzly Bars
Impact Plates
Truck Body Liners
Shot and Sand Blast Equipment
Pug Mill Paddles
Railroad Maintenance Equipment
Farm Machinery and Components
Transitions T-Injectors
Target Plates
Drag Line Bucket Liners
Bucket Lips
Spiral Chutes
Screw Conveyor Flights
Longwall Pans
Transfer Chutes
Cones
Bucket Heel Plates
Chipper Components
Chutes
Conveyor Components
Cyclone Components
Fan Blades
Fan Housing Components
Crusher Hammers
Hoppers
Impellers
Screen Plates
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Super-C Chemical Composition
|
Carbon
|
4.8%
|
|
Manganese
|
1.6%
|
|
Silicon
|
0.67%
|
|
Chromium
|
26.7%
|
|
Iron
|
Balance
|
ASTM A36 (other base material such as Stainless Steel available upon request)
Cladding:
A tough austenitic steel with a high chromium carbide concentration and dispersion reaching a minimum hardness of 600 BHN.
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Super-C Microstructure
The microstructure of Super-C is a mixture of high volume hexagonal shaped chromium carbides in a tough austenitic steel matrix. Through a proprietary process, the carbides are perpendicularly aligned to the surface of the clad, making them extremely difficult to dislodge or wear.
Surface Appearance:
All Super-C plates contain "check relief cracks". These cracks form transversely across the weld bead as the weld deposit cools and occur 3/4" to 2" apart. They are a inherent feature of this product and serve to relieve stresses within the plate. Studies have shown that the stress relief cracks propagate through the clad, but stop when they reach the low carbon steel base plate. The presence of check relief cracks prohibits the use of Super-C as a structural member. It is intended to be used as liner material for wear protection only.
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Super-C Welding Instructions
Super-C is normally supplied with plasma arc cut edges ready for welding. Welding to carbon steel support structures is accomplished with Multi Alloy 85 electrodes using the proper welding procedures. Care should be exercised to prevent the cladding portion of the plate from diluting the fillet weld.
Tri-Weld C hardfacing electrodes are used to provide protection to the fillet welds. Support structures other than carbon steel, such as aluminum or manganese steel, will require compatible electrodes and procedures.
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Cold Forming Super-C
Moderate forming can be satisfactorily performed in all thicknesses, provided adequate power is available and proper procedures are used. Generally, the power required to form Super-C will be approximately the same as required for low carbon steel. All forming should be done with the cladding on the inside radius to prevent spalling. Forming may result in an increase in cracking or chipping at existing crack sites.
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Cutting Super-C
Plasma arc cutting is recommended for shape cutting, piercing large holes and beveling Super-C. Cutting is most successful when cut is made from the low carbon steel sides, although some cuts may be made from the clad side. Conventional plasma arc cutting techniques and gases should be used.
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Grinding Super-C
Super-C cannot be machined using conventional methods. Grinding and EDM methods are the only proven satisfactory methods for precision removal of metal. When grinding, a hard-grit, soft-bond wheel is required. For non-precision metal removal and hole piercing, plasma arc and carbon arc gouging can be used successfully.
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Duracorr
Duracorr, a registered trademark of Arecelor Mittal Steel, is a low-cost, 11% chromium, dual phase steel plate. When compared to weathering, painted or galvanized steels, it has life-cycle cost advantages that permit its effective use in a wide variety of applications. Duracorr is formable and weldable. It can be produced to 50 ksi minimum yield strength with good toughness. Although less corrosion resistant than 300-series stainless steel grades, Duracorr is substantially more corrosion resistant than weathering, painted or galvanized steels. Duracorr develops a brown patina when used in non-abrasive, atmospheric conditions. Duracorr is listed in ASTM A240 as UNS designation S41003. The steel may be used in a number of applications requiring strength and corrosion resistance.
Technical Information
Applications
Chemical Composition
Processing Information: Welding, Forming, etc.
Engineering Data: Tensile Strength, Toughness, etc.
High Temperature Tensile Properties
Corrosion Behavior
Duracorr Applications
Below is a partial list of typical applications for Duracorr. Please contact Rich Fercy for more information.
Coal Cars
Coal Handling Equipment
Ore Cars
Cement Plant Equipment
Quarry Equipment
Floor Plate
Truck Salt Spreaders
Bus Frames
Electrical Transmission
Towers
Street Sweepers
Grain Hopper Cars
Fertilizer Handling and Storage
Fertilizer Hopper Cars
Sugar Beet Processing Equipment
Manure Hoppers and Spreaders
Storage Bins
Boat Docks
Drain Covers
Sewage Plant Equipment
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Duracorr Chemical Composition
Duracorr, a registered trademark of Mittal Steel, is produced to the chemical composition shown below, and is melted and refined by the Vacuum Oxygen Decarburization (VOD) process. It exhibits a fine-grain, dual phase microstructure of ferrite plus tempered martensite.
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Duracorr Processing
Duracorr exhibits a fine-grained microstructure of ferrite and tempered martensite that imparts attractive fabrication characteristics. Duracorr is formable and weldable when the guidelines below are followed.
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Cold Forming
Due to its higher yield strength levels, Duracorr requires higher forming loads than mild steel-such as ASTM A36-during bending and other cold forming operations. It also exhibits slightly more spring-back.
When bending Duracorr with sawed, plasma-cut or ground edges, a 1/2t (t = thickness) minimum bend radius should be observed.
If the edges are sheared, the 1/2t radius only applies to bends perpendicular to the major rolling direction. Bends parallel to the major rolling direction should use a 2t minimum bend radius. The 1/2t guideline may be used for all orientations if the complete cold worked sheared edge (face and burr) in the location of the bend is ground removing approximately 0.05".
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Welding
Duracorr is weldable with most standard electric arc and resistance welding techniques, providing appropriate procedures are followed. Duracorr can be welded to itself and to stainless and carbon steels. It does not develop the higher hardness associated with martensitic stainless steels, nor the coarse-grain, low-toughness properties found in ferritic stainless steels. The dual phase microstructure of austenite plus ferrite in the heat-affected zone during welding limits grain growth in the HAZ, enhancing toughness in weld areas. Due to the variety of steels and welding processes used, the following general guidelines are recommended for welding Duracorr.
Welding qualification procedures should be established for each welding process using AWS D1.1. Contact Rich Fercy if assistance is required.
Electrodes of the AWS 309L, 308L, 316L types or equivalent should be used with the current settings at the low to middle range recommended by the electrode manufacturer. Use of AWS 309L is preferred when welding Duracorr to other steels.
The heat input during welding should be minimized to produce a weldment (weld and heat affected zone) with optimum properties.
The SMAW, GMAW, GTAW and FCAW processes have been routinely used. Because of the high heat input inherent in SAW, it is rarely used. When SAW is used, care must be taken to minimize dilution of the weld metal.
A plate temperature of +60°F is recommended for Duracorr. If the steel being welded to Duracorr requires additional preheat, the requirements for that steel should be followed.
Parts to be welded should be free of loose or thick scale, moisture, grease or other foreign materials that could influence weld quality.
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Engineering Data
Ultimate Tensile Strength, min 66 ksi 455 MPa
Yield Strength, min 40 ksi 275 MPa
Elongation in 2", min 18%
Brinell Hardness, max. 300 BHN
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High Temperature Tensile Properties
Duracorr may be considered for high temperature applications. To assist in evaluating its applicability, the figure below presents a comparison of yield strength properties versus other steels. Note that up to 1000°F Duracorr demonstrates similar strength properties to Type 304 stainless steel. It is not recommended that Duracorr be used at temperatures above 800°F without considering creep design procedures. High temperature stress-rupture and creep data were developed for Duracorr. Check with Rich Fercy for the latest available information.
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Corrosion Behavior
Often, Duracorr may be in contact with carbon steel in the fabrication of different products. Such a design feature may promote galvanic corrosion. When two different metals touch in a corrosive solution, a "galvanic couple" is created and accelerated corrosion of the less corrosion-resistant metal occurs. This effect can be reduced if the surface area of the carbon steel is large compared to the area of Duracorr. If the reverse is present, for example, carbon steel rivets in Duracorr the carbon steel will corrode at a significantly higher rate. Therefore, it is important to use stainless rivets, bolts or interior structural elements, if Duracorr is in contact with a corrosive environment. The environment in which Duracorr is used dictates its applicability. Duracorr has been used in challenging corrosive applications including rail cars and equipment for processing high sulfur coal, water tanks in street sweepers, and processing equipment for sugar beets. Contact Rich Fercy to review other specific environmental applications.
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