Upholding Quality from Raw Materials to Finished Weld Overlay Wear-Resistant Plates: Xinyuan Botong's Independent R&D Builds a Comprehensive Quality Assurance Line
In heavy-duty wear-resistant fields such as metallurgy, coal, cement, and electric power, the performance of wear-resistant plates directly determines equipment operating efficiency and maintenance costs, while the quality of the weld overlay is the key to the core competitiveness of wear-resistant plates. As the core raw material for weld overlay of wear-resistant plates, the stability of carbon and chromium content and the precision of impurity control in high-carbon chromium iron powder directly affect the formation of hard phases such as chromium carbide (Cr₇C₃, Cr₂₃C₆) in the weld overlay, thereby determining wear resistance. Shandong Xinyuan Botong High Chromium New Materials Co., Ltd. (hereinafter referred to as "Xinyuan Botong") has profound experience in the wear-resistant materials field. Driven by independent research and development, it has built a comprehensive quality assurance system covering the selection of high-carbon chromium iron powder raw materials to the delivery of finished weld overlay wear-resistant plates. It provides stable and reliable wear-resistant solutions for downstream industries through technological innovation and refined management and control.
I. Source Control: Precise Selection of Raw Materials Adapted to Weld Overlay Requirements
Stable quality starts with strict source control. Xinyuan Botong deeply recognizes the decisive role of raw materials in the performance of finished weld overlay products, and has established a three-in-one raw material quality system covering "resource screening - ratio optimization - supply chain management and control", ensuring the reliability of basic weld overlay raw materials from the source.
In the preparation of high-carbon chromium iron powder, the core raw material, Xinyuan Botong has formulated chromium ore screening criteria that far exceed industry standards. It prioritizes the selection of high-quality chromium ore resources from premium producing areas to avoid impurities affecting the density and wear resistance of the weld overlay.
In response to the special requirements of the weld overlay process for iron powder particle size, the particle size of high-carbon chromium iron powder is precisely controlled below 150μm through refined crushing and screening processes, ensuring excellent fluidity and uniform deposition during the spray powder-feeding weld overlay process. To solve the industry pain point of easy cracking and spalling of the weld overlay under high-stress impact working conditions, the R&D team has innovated through multi-alloy ratio, scientifically adding elements such as manganese, molybdenum, niobium, and titanium to high-carbon chromium iron powder to form a special composite raw material system. This system can form submicron-level composite carbides such as TiC, VC, and NbC in the weld overlay, significantly improving the hardness and impact toughness of the weld overlay.
The stability of the supply chain is the guarantee for the continuous controllability of raw material quality. Xinyuan Botong has established a diversified supplier cooperation network and signed long-term strategic agreements with high-quality chromium ore and alloy raw material suppliers to ensure the stable supply of core resources. At the same time, drawing on the supply chain management experience of cladding alloy weld overlay wear-resistant plate projects, it implements strict incoming inspection processes, conducts comprehensive inspections on each batch of raw materials in accordance with incoming material operation guidelines and product standards, and eliminates unqualified raw materials from entering the production process at the source.
II. Independent R&D: Breaking Through Technical Bottlenecks in Core Weld Overlay Processes
The quality advantages of raw materials need precise empowerment of core processes to be transformed into high-quality weld overlay finished products. Xinyuan Botong focuses on the technical pain points of wear-resistant plate weld overlay, and has built a comprehensive technical system covering raw material preparation, weld overlay processes, and intelligent control through independent R&D, providing solid support for quality stability.
In the innovation of weld overlay processes, the optimal process parameters have been determined through a large number of experiments: when the powder-feeding speed is 800g/h and the powder-feeding gas flow rate is 5L/min, the wear resistance of the weld overlay is more than 4 times higher than that of traditional welding wire weld overlay. The independently developed open-arc weld overlay flux-cored wire has the characteristics of smooth wire feeding, stable electric arc, and low spatter, with a deposition efficiency of up to 92%. The welding process does not require gas or flux protection, simplifying the process while ensuring the stability of weld overlay quality. Process parameters are automatically adjusted through data feedback to ensure uniform composition and consistent performance of the weld overlay.
III. Full-Process Control: Refined Quality Assurance from Iron Powder to Finished Products
Adhering to the concept that "every link is a quality checkpoint", Xinyuan Botong implements refined management and control throughout the entire process from the production of high-carbon chromium iron powder to the finished weld overlay wear-resistant plates, and has established a comprehensive management and control system covering process control, inspection, and finished product processing.
In process control, a multi-inspection model of IPQC inspection, employee self-inspection, and team mutual inspection is implemented to fully monitor key processes such as pre-reduction, refining, and cooling forming in the production of high-carbon chromium iron powder, as well as preheating, welding, and post-heating in the weld overlay of wear-resistant plates. For the pre-reduction stage, the temperature of the vertical furnace is precisely controlled at 1200-1300℃ to ensure the full reduction of chromium ore; in the refining stage, impurities are removed through special slag formers, controlling the impurity content below 0.5%; during the weld overlay process, the welding current, voltage, and speed are strictly controlled to avoid defects such as porosity, slag inclusion, and undercut.
In the quality inspection link, high-precision imported testing equipment is equipped to build a "raw material - process - finished product" comprehensive inspection system. In the raw material stage, the focus is on testing chromium content, carbon content, and particle size distribution; in the process stage, equipment such as X-ray diffractometers and metallographic microscopes are used to analyze the microstructure and phase composition of the weld overlay; in the finished product stage, key indicators such as surface hardness, wear resistance, and bonding strength are fully tested, and the C=0 sampling plan is adopted for outgoing inspection to ensure zero outflow of unqualified products. To enhance quality credibility, finished products are proactively sent to third-party authoritative institutions for testing, covering physical properties, chemical composition, and wear resistance, verifying quality strength through authoritative certification.
IV. Innovation-Driven: Technological Iteration and In-depth Adaptation to Application Scenarios
Continuous technological innovation is the core driving force for the stable improvement of quality. Xinyuan Botong has always adhered to the quality policy of "technological innovation and continuous improvement", and continuously built a long-term quality assurance mechanism through industry-university-research cooperation, patent layout, and demand-oriented innovation.
It focuses on key technical fields such as high-stress impact wear and high-temperature-resistant weld overlay for research, and has successfully developed plasma weld overlay flux-cored wire preparation technology resistant to high-stress impact wear, solving the industry problem of easy spalling of the weld overlay under high-impact working conditions. Up to now, it has formed a core technical barrier covering fields such as high-carbon chromium iron powder preparation and weld overlay process optimization. According to the application characteristics of different industries, customized solutions are developed: providing high-temperature and wear-resistant weld overlay finished products for sintering silo liners and crusher components in the metallurgical industry; providing high-impact wear-resistant solutions for conveyor trough liners and truck trough liners in the coal industry; providing high-hardness wear-resistant products for mill liners and vibrating screens in the cement industry, achieving precise adaptation of quality to application scenarios.
V. Full-Lifecycle Assurance: Quality Closed Loop from Delivery to After-Sales Service
Xinyuan Botong believes that quality assurance should not end with the delivery of finished products, but should extend to the entire product lifecycle. It has established a comprehensive quality assurance system covering packaging, transportation, and after-sales service to ensure that products arrive at customers in the best condition.
In the packaging and transportation link, customized protection schemes are adopted according to product types: finished wear-resistant plates are packaged with anti-collision and moisture-proof materials, equipped with special fixing devices to avoid collision damage during transportation. Logistics companies with rich experience in wear-resistant material transportation are selected, transportation routes are reasonably planned, and transfer links are reduced to ensure the safe delivery of products.
In after-sales support, a sound customer feedback and quality traceability mechanism is established. Customer usage feedback is collected through telephone, email, on-site visits, etc. For customer-complained products, root cause analysis is conducted, corrective and preventive measures are formulated and verified for effectiveness, forming a virtuous cycle of quality improvement. Relying on the unique product batch number, full-process traceability from raw material procurement, production and processing to finished product delivery is realized. In case of quality problems, the root cause can be quickly located and accurately rectified. At the same time, full-process technical support is provided to customers, including weld overlay process guidance and installation and commissioning suggestions, to ensure that products exert the best performance.
From the precise selection of high-quality raw materials to the independent innovation of core processes; from refined full-process control to full-lifecycle quality assurance, Xinyuan Botong has built a comprehensive quality assurance system from high-carbon chromium iron powder to finished weld overlay wear-resistant plates based on the concept of "quality first, integrity and pragmatism". In the future, Xinyuan Botong will continue to deepen technological innovation, continuously optimize the quality management and control system, and empower the high-quality development of metallurgy, coal and other industries with more stable products and better solutions, demonstrating the quality responsibility and technical strength of Chinese wear-resistant material enterprises.