Ceramic Wear Plates

Material Properties

Hardness: 1500-2000 HV (Vickers Hardness)

Temperature Resistance: Up to 2000°C (3632°F)

Material Types: Alumina (Al₂O₃), Zirconia (ZrO₂), Silicon Carbide (SiC)

Typical Thickness: 6mm - 50mm

Density: 3.6-3.9 g/cm³ (Alumina), 5.6-6.0 g/cm³ (Zirconia), 3.1 g/cm³ (SiC)

Ceramic Types

Alumina (Al₂O₃):

• Most common ceramic wear material
• Excellent abrasion resistance
• Good chemical resistance
• Cost-effective option
• Available in 92%, 95%, and 99.7% purity

Zirconia (ZrOâ‚‚):

• Higher toughness than alumina
• Better impact resistance
• Excellent wear resistance
• Higher cost than alumina

Silicon Carbide (SiC):

• Highest hardness among ceramics
• Excellent thermal conductivity
• Superior chemical resistance
• Best for extreme abrasion

Advantages

• Exceptional hardness - Much higher than steel (10-15x harder than AR500)
• Extremely high abrasion resistance - Superior wear life
• Chemical inertness - Resistant to acids, alkalis, and corrosive materials
• Lightweight - Lower density than steel
• High temperature resistance - Can operate at temperatures where steel fails
• Non-magnetic - Suitable for applications requiring non-magnetic materials

Applications

• Industrial high-temperature zones
• Cyclones and separators
• Chutes and transfer points
• Slurry handling systems
• Cement plant lining systems
• Power plant wear zones
• Pipe elbows and bends
• Mixing equipment
• Coal-fired power plants
• Mineral processing equipment

Installation Methods

Adhesive Bonding: Ceramic tiles bonded to steel backing plates using high-strength epoxy or polyurethane adhesives.

Mechanical Fastening: Ceramic pieces held in place with mechanical fasteners or retention systems.

Rubber Backing: Ceramic tiles embedded in rubber for impact absorption and flexibility.

Welded Studs: Steel backing plates with welded studs, ceramic tiles secured with nuts.

Limitations

• Brittleness - Low impact toughness, can crack or shatter under heavy impact
• Installation complexity - Requires specialized installation techniques
• Higher initial cost - More expensive than steel plates
• Thermal shock sensitivity - Rapid temperature changes can cause cracking
• Not suitable for structural loads - Cannot bear significant structural loads

Selection Guidelines

Choose Alumina when: Cost-effectiveness is important, and moderate abrasion resistance is sufficient.

Choose Zirconia when: Higher impact resistance is needed along with excellent wear resistance.

Choose Silicon Carbide when: Maximum abrasion resistance and chemical resistance are required, especially at high temperatures.

Comparison with Steel Plates

vs. AR600: Ceramics offer 5-10x better abrasion resistance and can operate at much higher temperatures, but have lower impact toughness.

Wear Life: Ceramic liners typically last 5-20x longer than steel in extreme abrasion applications.

Cost Justification: Higher initial cost offset by dramatically extended service life and reduced downtime.

Best for: Extreme abrasion environments, high-temperature applications, and corrosive conditions where steel cannot perform adequately.