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www.totalsteel.com.au total quality total service Total Steel wear plate high strength abrasion resistant
www.totalsteel.com.au
total quality total service Total Steel
wear plate
high strength abrasion resistant
A U S T R A L I A
PerthPhone: (08) 9351 6800Fax: (08) 9351 6868Email: [email protected]
DarwinPhone: (08) 8984 4324Fax: (08) 8947 4615Email: [email protected]
MelbournePhone: (03) 9369 8855Fax: (03) 9369 8866Email: [email protected]
SydneyPhone: (02) 4648 8111Fax: (02) 4647 8011Email: [email protected]
AdministrationPhone: (02) 8508 4800Fax: (02) 9520 8628Email: [email protected]
BrisbanePhone: (07) 3723 9200Fax: (07) 3271 1699Email: [email protected]
Locations
Mining equipment endures heavy pounding and abrasion during round-the-clock operations at Australia’s largest gold mining venture. Total Steel offers the solutions
to wear problems - increasing productivity and reducing downtime.
Total Steel is dedicated to bringing the benefits of the latest in wear plate technology to Australasian industry. Mining, construction and farming industries in our part of the globe demand high grade materials that perform efficiently and reliably under our unique harsh conditions.
With our vast range of knowledge and experience, Total Steel is in a position to give expert advice on the right materials for your industry, and vital information on how best to utilise them.
Total Steel of Australia is the principal stockist and distributor of JFE abrasive resistant and high strength plate in Australia. Pioneered in the mid 1950s these products are used in the manufacture and refurbishment of equipment in construction, civil engineering, mining and farm equipment.
The JFE product range has exceptional features:
● free of mill scale
● hardness consistency
● superb weldability
● exceptional flatness
● thru-hardened, to avoid soft spots
Massive haul trucks crawl up a mine access road prior to dumping overburden. EHSP’s superior abrasion resistance is ideally suited for wear liner plates in these hard working vehicles.
Mining companies and contractors benefit by using EHSP as wear protection components in grizzly screens.
Total Steel stocks a wide range of JFE wear plate products specifically formulated to perform in a variety of applications. Each product displays different characteristics which make it suitable for a particular purpose. Your Total Steel branch will advise you the best JFE wear plate for your requirements.
The JFE RangeThese products feature excellent flatness and are easily welded using low hydrogen consumables.
EverhardEverhard 320 and 360 are wear plates with a minimum hardness of 321 and 361 Brinell (BHN) respectively. Both grades are thru hardened, free of mill scale and offer good ductility.
Everhard 360A is designed for applications where high impact may cause problems. EH-360A is supplied in thickness range 60 mm up to 100 mm.
Everhard 360LE is an abrasion resistant wear plate manufactured using Micro-alloying Technology and Controlled Heat Treatment. Benefits include excellent weldability and formability plus low temperature toughness. Available from 6 to 32 mm thicknesses.
Everhard 500LE, also manufactured using Micro-alloying Technology and Controlled Heat Treatment, is used for applications requiring very high abrasion resistance. Weldability, formability and low temperature toughness are also excellent. Available from 6 to 40 mm thicknesses.
EHSP. Total Steel of Australia have been working with several major companies in testing JFE’s new abrasion resistant plate EHSP. These tests proved to be extremely successful, demonstrating dramatically improved life of components manufactured from this new, super wear resistant plate.
HitenHiten 780S is produced in thicknesses up to 50 mm with alloying elements reduced to a minimum. This allows good weldability and high economy. This grade is particularly suited for use in mining, construction and industrial equipment.
Hiten 780F is produced in thicknesses greater than 50mm, and with a combination of outstanding low temperature notch toughness and good weldability. It is particularly suitable for the manufacture of mining equipment and other applications where weight reduction is an advantage. Hiten 780F is well suited to cutting edges on large earthmoving buckets because of its high toughness and good weldability. Total Steel stocks up to 150 mm 780F for use on bucket cutting edges.
Hiten 780LE, manufactured using TMCP (Thermo-Mechanical Control Process) and Micro-alloying Technology, combines low temperature toughness with high weldability. Thicknesses up to 40 mm.
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ucts
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Excavators need a highly abrasion resistant product such as EHSP to lengthen intervals between bucket overhauls.
Total Steel’s CNC controlled oxy cutting machine produces highly accurate components from EHSP, Hiten and mild steel plates.
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ices
To maximise the benefits of superb JFE technology to our customers, Total Steel offers the following services:
● Our CNC controlled oxy and plasma cutting machines enable Total Steel to give customers the exact shapes they want when they want. This elim-inates costly mistakes and the need for our customers to carry the cost of stocking offcuts.
● Same day breakdown service at Total Steel is always available. For shutdowns, Total Steel offers a variety of labour saving services:
● Stud welding on wear liner plates to Australian Standards.
● Drilled and countersunk holes for wear liner plates.
● Digitizing of templates from cardboard cutouts or samples, for CNC cutting to shape on our machines ready for installation.
Solutions to abrasion problems are often complex. The vast variation in climatic conditions and geological formations in Australia means that wear solutions are often different from case to case.
The superb technology used to engineer JFE products makes them highly effective in avoiding equipment fatigue and failure. Mining equipment manufacturers appreciate these qualities as they benefit from good workability and cost savings.
services
Total Steel offers exact cut-to-size shapes from standard or custom templates, through to digitizing, plasma or oxy cutting, for prompt delivery to our Australasian-wide clients.
EHSPTITANIUM TUFF wear plateEHSP field tests in America have proved successful, and in a few short years, EHSP has won end-user acceptance with many operators in the mining and quarry industries.The savings in labour and increased production through fewer changeouts of wear plates has enabled maintenance personnel to channel their labour to other areas.
EHSP contains titanium carbides that have a hardness of 3200 vickers. These particles are dispersed throughout the steel plate during manufacture. This gives EHSP a superior abrasion resistance when compared with plates with similar or higher Brinell (BHN) hardness. This plate can replace 320, 360, 400, 450 and 500 BHN in a large number of applications.
Features of EHSP
● Produced by world leaders in wear plate technology
● Exellent flatness
● Hardness is minimum 400 BHN.
● EHSP can be successfully stud welded with a localised preheat of 150°C.
● The titanium particles added to the steel have a hardness of 3200 vickers.
● Using thinner plates as liners for dump truck bodies EHSP, can offer significant weight reductions to achieve greater payloads.
● Outstanding wear life
● User friendly for welding and working
EHSP has been dramatically successful in extreme environments which call for higher abrasion resistance than 500 BHN. Conventional wear plate design is based on the assumption that abrasion resistance rises as the hardness of the steel increases. This gives rise to problems in practical application since weldability and formability decreases with an increase in hardness beyond that of the 500 grades. JFE has solved this dilemma with EHSP.
For detailed welding information refer to our web site: www.totalsteel.com.au
Used as skid plates and liner plates, EHSP can be welded on site.
Results of field tests with EHSP in America and Canada
Loader bucket skid plates Gold 500 BHN Steel 60%
Chute liners Granite 500 BHN Steel 50%
Loader bucket heel plates Concrete 500 BHN Steel 50%
Truck body liner plates Copper 500 BHN Steel 55%
Crusher discharge hopper Copper 500 BHN Steel 52%
Crusher chute Copper 500 BHN Steel 52%
Truck body liner plate Gold 360 BHN Steel 300%
Dragline bucket shrouds Rock quarry 400 BHN Steel 90%
Ripper tooth Earthmoving Weld Overlay 12%
Coal chute Power plant 500 BHN Steel 60%
Vibratory feeder Gold 500 BHN Steel 40%
Shovel bucket Coal 400 BHN Steel 230%
Splitter gate Copper 400 BHN Steel 200%
Crusher parts Gold 500 BHN Steel 50%
Chute Rock quarry 450 BHN Steel 40%
Application Industry Compared with Extra Wear Life
Ultrasonic thickness testing confirms EHSP’s resistance to abrasive wear.
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WeldingJFE products have excellent weldability providing correct procedures are followed. Preheating varies with grade, plate thickness and restraint conditions in weld areas. Low hydrogen consumables are recommended.
Recommended Preheat Temperatures
Grade Thicknessmm
Shielded metal arc welding
Gas shielded arc welding
EH 320 20 75 50
EH 360 40 125 100
EH 360A 40 150 125
EH 360LE 1932
75100
2525
EH 500LE 20 32
125 175
75 125
EHSP 3650
120–175120–200
120–175120–200
Hiten 780S 2040
150150
150150
Hiten 780F 80100
150150
150150
Hiten 780LE 40 150 150
(Based on Y-groove weld cracking test results under high restraint.) Temp °C
Gas CuttingEverhard EH 320, EH 360, EH 360LE, Hiten 780S and Hiten 780LE These plates can be gas cut using normal methods.
Other grades require certain precautions:
EHSP and EH 500LETo prevent cracking from the cut surface, post-heating to 200°C is necessary on material over 20 mm. Thicknesses over 20 mm should be cooled evenly without any assistance and away from cool air. Care needs to be taken to prevent notches as these can cause the steel to crack. Heat input must be controlled when cutting into small shapes because hardness may be reduced.
Hiten 780F and EH-360AFor Hiten 780F and EH-360A, we recommend preheating to 150°C to ensure good quality cutting.
Drilling and CountersinkingEHSP and EH 500LE wear plates require replaceable carbide tipped inserts using robust drilling equipment to avoid tip chipping caused by excess movement. All other grades can be drilled with high speed drills provided care is taken although cobalt drills are preferred. Adequate lubrication is always essential.
MachiningPlate hardness determines the speed and cutting depth. When machining , carbide tipped cutting tools will perform best.
BendingBending or roll forming should be transverse to the rolling direction. Gas cut edges and notches should be dressed with a grinder to remove any heat affected zone (HAZ). Quenched and tempered plates require larger bending radii than mild steel plates.
t = plate thickness
Grade Minimum Bending Radius
EH 320 4.5 x t
EH 360 4.5 x t
EH 360A 4.5 x t
EH 360LE 4.5 x t
EH 500LE 6 x t
EHSP 6 x t
Hiten 780S 4.5 x t
Hiten 780F 4.5 x t
Hiten 780LE 4.5 x t
working with JFE productsRecommendations for Welding and Fabrication
Drilling and countersinking using carbide tipped drilling equipment.
Intricate shapes accurately profile cut.
product analysis
DISCLAIMERInformation contained within this document is subject to change without notice. Total Steel of Australia Pty Ltd makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties or fitness for a particular purpose. Total Steel of Australia Pty Ltd shall not be liable for errors contained herein or for incidental consequential damages in connection with the performance or use of this material.
Stud welding to wear plate enables rapid fitting of wear plate liners to chutes, feed slots and hoppers.
Typical Mechanical Properties
Grade Thickness Tensile Test L Direction Hardness Charpy Impact Test
mm Yield Point N/mm2
Tensile Strength N/mm2 Elongation % Brinell Hardness 0°C
(J)-50°C
(J)
EH 320 19 960 1015 20.1 377 – –
EH 360 19 40
1080 930
1197 1152
25.6 16.5
385 419
52 43
– –
EH 360A 19 1129 1184 25.3 388 156 62
EH 360LE 1930
1058927
13081178
23.018.0
411402
61 [-40°C (J)]47 [-40°C (J)]
EH 500LE 20 1203 1681 17.0 502 42 [-40°C (J)]
EHSP 12 35
1270* 1098*
1489 1349
13.2 11.3
461 455
24 18
– –
*0.2% proof stress -5°C (J)
-20°C (J)
Hiten 780S 19 40
773 758
821 835
29.6 23.3
– –
115 150
51 55
Hiten 780F 25 40
809 774
854 833
20.0 24.3
– –
– –
159 162
Hiten 780LE 32 743 809 26 – – 145
Typical Chemical Composition
Grade Thickness mm C Si Mn P S Cu Ni Cr Mo V Ti B Zr Ceq
EH 320 19 0.1 0.4 1.5 0.019 0.005 – – 0.3 – – 0.010 0.0010 – 0.4
EH 360 19 40
0.2 0.2
0.3 0.3
1.4 1.4
0.020 0.020
0.006 0.006
– –
– –
0.3 0.3
– –
– –
0.006 0.006
0.0015 0.0015
– –
0.5 0.5
EH 360A 19 0.2 0.3 1.0 0.014 0.003 – – 0.6 0.2 0 0.014 0.0010 – 0.5
EH 360LE 19 32
0.17 0.17
0.55 0.55
1.6 1.6
0.020 0.020
0.010 0.010
– – 0.04 0.04
0.35 0.35
– –
0.02 0.02
0.004 0.004
– _
0.40 0.43
EH 500LE 19 32
0.29 0.29
0.55 0.55
1.6 1.6
0.020 0.020
0.010 0.010
– –
– –
0.40 0.40
0.35 0.35
– –
0.02 0.02
0.004 0.004
– –
0.55 0.58
EHSP see note 1
12 35
0.29 0.30
0.34 0.33
0.69 0.68
0.007 0.007
0.001 0.001
– –
– –
0.93 0.93
– –
– –
– –
– –
– –
– –
Hiten 780S 19 40
0.2 0.2
0.4 0.4
1.5 1.5
0.025 0.025
0.009 0.009
– –
– –
0.2 0.2
– –
– –
0.008 0.008
0.002 0.002
– –
0.5 0.5
Hiten 780F 25 40
0.2 0.1
0.3 0.3
0.8 0.7
0.011 0.017
0.006 0.009
0.2 0.2
– –
0.9 0.9
0.3 0.5
0 0
– –
0.002 0.002
0.1 –
0.55 0.56
Hiten 780LE 19 32
0.13 0.20
0.15 0.40
1.0 1.4
0.025 0.025
0.015 0.015
– –
– –
0.20 0.20
0.15 0.15
– –
– –
0.005 0.003
– –
0.40 0.43
Ceq for EH 320, 360, 360A and 500 = C + Mn/6 + Si/24 + Cr/5 + Mo/4 + V/15Ceq for EH 360LE, 500LE = C + Mn/6 + Cu/15 + Ni/15 + Cr/5 + Mo/5 + V/5Ceq for Hiten 780S, 780F and 780LE = C + Si/24 + Mn/6 + Ni/40 + Cr/5 + Mo/4 + V/14Ceq for Hiten 780LE = C + Mn/6 + (Cu + Ni)/15 + (Cr + Mo/4 + V)5
Note 1 – Other alloying elements are added for enhancing the abrasion resistant property.
Total Steel of Australia Pty LtdABN 34 001 201 850
AdministrationSuite 10, 35–37 Railway ParadeEngadine, New South Wales 2233PO Box 70 Engadine NSW 2233
Telephone: (02) 8508 4800Fax: (02) 9520 8628
Email: [email protected]
Sydney46 Anzac Avenue
Smeaton Grange, New South Wales 2567Box 3205 Narellan DC NSW 2567
Telephone: (02) 4648 8111Fax: (02) 4647 8011
Email: [email protected]
Melbourne207-211 Fitzgerald Road
Laverton North, Victoria 3026PO Box 477 Laverton VIC 3028
Telephone: (03) 9369 8855Fax: (03) 9369 8866
Email: [email protected]
Brisbane106 Mica Street
Carole Park, Queensland 4300PO Box 265 Carole Park QLD 4300
Telephone: (07) 3723 9200Fax: (07) 3271 1699
Email: [email protected]
Perth53–75 McDowell Street
Welshpool, Western Australia 6106PO Box 626 Welshpool DC WA 6986
Telephone: (08) 9351 6800Fax: (08) 9351 6868
Email: [email protected]
Darwin48 Dawson Street, East Arm
Northern Territory 0822Telephone: (08) 8984 4324
Fax: (08) 8947 4615Email: [email protected]
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