Abrasion resistant plates are specialty steels engineered to withstand severe surface wear, abrasion, and material grinding in demanding industrial environments. These plates are significantly harder and longer-lasting than conventional carbon steel, which makes them indispensable in industries that regularly handle heavy bulk materials, abrasive feedstocks, or high friction contact surfaces.
Because wear is one of the most common causes of equipment failure, abrasion resistant plates help reduce maintenance costs, extend component life, and improve plant uptime.
What Are Abrasion Resistant Plates?
Abrasion resistant plates (often called AR plates) are quenched and tempered steels produced with a specific chemical composition and heat treatment process to achieve high hardness levels. They are typically measured by Brinell hardness (HBW), with common grades including:
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AR360 / 360 BHN
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AR400 / 400 HBW
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AR450 / 450 HBW
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AR500 / 500 HBW
The higher the hardness value, the more resistant the plate is to abrasive wear. These plates combine high surface hardness with enough toughness to withstand impact and structural loads.
How Abrasion Resistant Plates Resist Wear
Abrasion resistant plates gain their performance through:
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Controlled alloying (carbon, manganese, chromium, molybdenum, etc.)
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Quenching and tempering heat treatment processes that harden the steel surface
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Microstructure control that balances hardness and toughness
The result is a plate where the surface is hard enough to resist micro-cutting and gouging by abrasive particles, while the core remains tough enough to absorb shocks and impacts.
Published technical research on AR steels shows that properly heat-treated steel with a high hardness level significantly increases wear life compared to mild steel. (General metallurgical data supports this hardness-wear correlation.)
Common Grades and Their Uses
Abrasion resistant plates are grouped by hardness grade. Each grade suits a different level of wear severity:
AR360 (360 HBW)
Good for moderate abrasion conditions where impact or structural toughness is also required.
AR400 (400 HBW)
One of the most widely used grades; suitable for a broad range of sliding abrasion applications such as feed chutes, hoppers, and material handling surfaces.
AR450 (450 HBW)
Offers enhanced wear resistance over AR400 for more severe applications like ore and aggregate handling.
AR500 (500 HBW)
High hardness for severe abrasion environments, often used in ballistic applications, high-impact liners, and mining equipment.
These grades are equivalent to wear plate specifications from major producers and wear plate standards referenced by industry.
Mechanical Properties
Abrasion resistant plates are designed to provide high strength and durability, which are essential for heavy wear applications. Typical characteristics include:
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High tensile strength compared to mild steel
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High hardness for abrasion resistance
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Sufficient toughness to resist cracking under impact
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Good elongation and ductility for forming and fabrication
Hardness values correlate directly with wear performance in abrasion tests such as ASTM G65 dry sand/rubber wheel testing.
Fabrication and Welding
Abrasion resistant plates can be fabricated using standard industrial methods but with specific considerations:
Cutting:
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Plasma, laser, or water-jet cutting is preferred
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Oxygen cutting can be used but may require edge preparation
Welding:
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Preheat may be recommended depending on thickness and grade
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Low hydrogen welding electrodes or filler metal matched to base metal hardness
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Controlled heat input to maintain weld and base material properties
Forming/Bending:
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Higher hardness grades like AR450 or AR500 require larger bend radii compared to mild steel
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Specialized jigs help prevent cracking
Proper fabrication ensures the plate’s wear resistance is maintained in service.
Typical Industrial Applications
Abrasion resistant plates are used wherever surface wear is a dominant failure mode:
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Mining equipment liners (buckets, hoppers, dump truck bodies)
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Aggregate, sand, and gravel handling systems
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Bulk material chutes and screens
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Crusher liners and impact surfaces
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Cement plants and steel mill wear points
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Coal handling systems and recycling machinery
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Earthmoving and construction equipment
In each of these environments, AR plates significantly outlast mild steel and cut overall operating costs.
Advantages of Abrasion Resistant Plates
Choosing proper abrasion resistant plate material offers several benefits:
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Longer component life under abrasive service
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Lower maintenance and downtime costs
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Improved operational efficiency due to reduced replacements
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Design flexibility with multiple hardness grades
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Compatibility with standard fabrication methods
These advantages make AR plates a smart investment in heavy wear environments.
Selecting the Right Grade
Selecting an abrasion resistant plate depends on:
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Type of wear (sliding vs impact)
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Hardness requirement (higher Brinell value for severe abrasion)
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Impact severity (toughness vs hardness balance)
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Fabrication and forming needs
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Operating environment
Generally, engineers choose a grade that maximizes wear life while still allowing fabrication and toughness needed for the application.
Conclusion
Abrasion resistant plates are engineered steels designed to perform where regular structural steels fail. Their high hardness, combined with balanced toughness, helps equipment resist abrasive wear and extend service life across demanding industrial operations.