JH-800K Dual-Torch Four-Wire Wear Plate Hardfacing Machine
Precision automated overlay welding for bimetal and CCO wear plate production.
The JH-800K is JINHUA’s advanced automated flat-plate overlay welding system developed for controlled and repeatable production of wear-resistant plates.
The system combines a dual-torch, four-wire welding configuration with Siemens PLC control, precision servo motion, servo-controlled wire feeding, automatic alloy powder feeding, real-time position monitoring and circulating water cooling.
Dual-Torch Four-Wire Platform Capabilities
The system combines a dual-torch, four-wire welding configuration with Siemens PLC control, precision servo motion, servo-controlled wire feeding, automatic alloy powder feeding, real-time position monitoring and circulating water cooling.
What Is the JH-800K Wear Plate Hardfacing Machine?
The JH-800K is an automatic overlay welding machine designed to deposit wear-resistant alloy onto a carbon steel base plate.
During production, welding wire and alloy powder are deposited onto the base plate while the machine precisely controls:
- Welding carriage movement
- Wire feeding rate
- Powder feeding
- Welding travel speed
- Torch oscillation
- Welding position
- Cooling
- Deposition parameters
The deposited alloy forms a metallurgically bonded wear-resistant layer over the structural steel substrate.
This makes the JH-800K particularly suitable for manufacturers that require repeatable production quality while reducing dependence on manual welding operators.
Automatic overlay welding platform — dual torches, four-wire feeding, PLC control and circulating water cooling.
Dual-torch overlay welding in progress — two welding torches depositing wear-resistant alloy simultaneously.
Why Choose a Dual-Torch Four-Wire Hardfacing System?
More deposition capability with controlled welding. The JH-800K combines two welding torches with a four-wire feeding configuration.
More Deposition Capability with Controlled Welding
The JH-800K combines two welding torches with a four-wire feeding configuration. The system is designed to increase deposition capability while maintaining controlled wire feeding and welding stability.
Compared with conventional manual or lower-automation hardfacing processes, the system provides more consistent control over:
- Wire deposition rate
- Welding bead width
- Overlay thickness
- Bead overlap
- Welding trajectory
- Alloy powder addition
- Heat input
This allows wear plate manufacturers to establish a more repeatable production process.
Core Advantages of the JH-800K
Fifteen integrated systems covering control, motion, feeding, welding patterns, process monitoring and thermal management.
Siemens PLC Digital Control System
The Siemens PLC is the central control platform, coordinating welding, motion, wire feeding, powder feeding, position monitoring and auxiliary systems, with closed-loop control, digital parameter setting and alarm management.
Precision Servo-Controlled Welding Carriage
A TECO servo system controls carriage positioning and travel. Carriage coordinates are displayed continuously, and rapid non-welding travel reaches up to 9800 mm/min.
Servo-Controlled Four-Wire Feeding
Servo-based wire delivery is more accurate and repeatable than open-loop feeding, directly influencing deposition rate, arc stability, overlay thickness and bead shape.
Wire + Alloy Powder Hybrid Hardfacing
Controlled powder addition adjusts chromium content, carbon content, carbide formation, alloy composition, overlay hardness and wear resistance.
Precision Automatic Powder Feeding
A precision drive and motor control configuration maintains consistent powder delivery, improving deposition repeatability and reducing unnecessary consumable usage.
Multiple Overlay Thickness Control Modes
Multi-mode servo deposition control provides more flexibility than travel-speed-only adjustment, supporting an overlay thickness range of approximately 2–20 mm.
Adjustable 10–60 mm Torch Oscillation
An adjustable oscillation width of approximately 10–60 mm controls bead width, bead overlap, surface coverage, heat distribution and deposition uniformity.
Straight-Line, Grid and Oscillation Welding
Three welding patterns: straight-line welding for parallel bead deposition, oscillation welding to increase bead width, and programmed grid-type welding.
Broken-Wire Detection and Automatic Recovery
Automatic wire-break detection and alarm functions locate the interruption point so the missing weld section can be completed, avoiding plate rejection.
Water-Cooled Welding Torch System
Continuous circulating water cooling maintains torch thermal stability during long-duration welding, improving consumable life and reducing overheating risk.
Active Base Plate Water Cooling
A variable-frequency circulating water system controls plate temperature during welding, reducing heat accumulation and helping minimise deformation of large flat plates.
Real-Time Welding Coordinate Display
Carriage position is monitored throughout the welding cycle, improving process visibility during setup, welding, position adjustment and wire-break recovery.
10.2-Inch Touchscreen HMI
A 10.2-inch full-color touchscreen displays operating status, welding parameters, motion and position information, alarms and system feedback in Chinese or English.
Wireless Remote Operation
A wireless handheld terminal allows selected movements and adjustments during plate positioning, setup, torch positioning, commissioning and maintenance.
One-Button Automatic Production
After process parameters are set, the programmed hardfacing cycle runs automatically. One trained operator can supervise multiple machines under standardized production conditions.
Four Operating Modes for Flexible Production
The JH-800K is designed with multiple operating modes to meet different production and commissioning requirements.
Depending on the selected process, the system can control:
- Welding speed
- Wire feeding
- Powder feeding
- X-axis movement
- Overlay deposition
- Welding pattern
In manual mode, individual mechanisms can also be operated independently in both directions.
Siemens PLC cabinet & 10.2″ touchscreen HMI — centralized monitoring of welding, motion, feeding and alarm status.
Servo-controlled four-wire feeding — accurate and repeatable wire delivery during continuous hardfacing.
Wear Plate Production Process
The typical JH-800K production workflow — from plate loading to the finished wear plate.
Load the Base Plate
Place the Q235, Q345 or other suitable low-carbon steel base plate onto the machine working platform.
Position the Plate
Set the base material to the required welding starting position.
Select Welding Mode
Choose the required production mode according to overlay thickness and welding process.
Enter Welding Parameters
Set the following process parameters:
- Welding length
- Welding width
- Travel speed
- Wire feeding parameters
- Powder feeding parameters
- Oscillation width
- Welding trajectory
Start Automatic Hardfacing
The machine automatically controls wire feeding, powder feeding and welding movement.
Real-Time Process Monitoring
PLC and touchscreen continuously monitor machine status, welding position and operating conditions.
Base Plate Cooling
The circulating cooling system controls excessive heat accumulation and helps reduce plate deformation.
Automatic Wire-Break Detection
If wire feeding is interrupted, the machine generates an alarm and assists with locating the interrupted position.
Complete Overlay Welding
After the programmed welding area is completed, the finished wear plate can proceed to cooling and subsequent fabrication.
JH-800K Machine Details
The JH-800K platform integrates welding, motion, wire feeding, powder feeding, position monitoring and auxiliary systems.
Dual-torch welding head — two torches with four-wire feeding and adjustable oscillation.
Machine structure & guide system — servo-driven welding carriage on the horizontal frame.
Welding platform — base plate support and working area up to 1550 × 3200 mm.
Feeding & auxiliary systems — wire feeding, powder feeding and cooling connections.
Machine configuration — standard dual-torch four-wire build.
Production-ready platform — one-button automatic hardfacing cycle for wear plate production.
What Wear Plates Can the JH-800K Produce?
With suitable welding consumables and process parameters, the platform can be configured for bimetal, chromium carbide overlay and customized alloy wear plates.
Bimetallic Wear Plate
a structural carbon steel base plate combined with a welded wear-resistant alloy surface.
Chromium Carbide Overlay Plate
produced with suitable chromium carbide hardfacing consumables and process parameters.
Customized Alloy Wear Plate
overlay chemistry adjusted according to the intended wear environment.
Bimetallic Wear Plate
A structural carbon steel base plate combined with a welded wear-resistant alloy surface. The base steel provides structural strength and weldability, while the alloy overlay provides abrasion resistance.
Customized Alloy Wear Plate
Because the machine supports both welding wire and alloy powder addition, the overlay chemistry can be adjusted according to the intended wear environment. This provides additional flexibility for developing wear-resistant plates for different industrial applications.
Chromium Carbide Overlay Plate
When the JH-800K is operated with suitable chromium carbide hardfacing consumables and process parameters, it can be used for chromium carbide overlay (CCO) plate production. The final hardness, carbide structure and chemical composition depend on:
Welding wire
Alloy powder
Powder addition ratio
Welding current
Travel speed
Heat input
Number of overlay layers
Advantages of Wire + Powder Hardfacing
The combination of welding wire and alloy powder provides several potential manufacturing advantages.
Flexible Alloy Formulation
Additional alloying elements can be introduced through controlled powder feeding.
Adjustable Hardness
Overlay chemistry can be optimized according to the required hardness and wear mechanism.
Consumable Cost Optimization
The combination of wire and powder provides manufacturers with additional options for optimizing consumable formulation and production cost.
Customized Wear Performance
Different alloy formulations can be developed for abrasion, erosion and other wear conditions.
Finished Plate Characteristics
With suitable welding consumables and optimized process parameters, the JH-800K is designed to support the production of hardfaced plates with:
- Strong metallurgical bonding
- Controlled overlay thickness
- Low dilution
- Dense deposited alloy structure
- Consistent welding bead formation
- Controlled plate deformation
- Adjustable alloy composition
- Adjustable hardness
- Relatively flat finished surface
- Repeatable batch production
Actual finished plate properties depend on welding consumables, alloy composition and process parameters.
Weld bead overlap & surface consistency — the visible result of servo-controlled deposition.
Typical Applications of Finished Wear Plates
Wear plates produced using the JH-800K can be fabricated into liners and wear-resistant components for industries including:
Mining
- Chute liners
- Hopper liners
- Crusher liners
- Transfer point liners
- Conveyor wear liners
Cement
- Chute liners
- Separator components
- Grinding system wear parts
- Duct liners
- Material handling liners
Steel Mills
- Raw material handling liners
- Sintering equipment liners
- Conveyor components
- Wear-resistant processing components
Power Plants
- Coal handling systems
- Ash handling systems
- Chutes
- Wear-resistant ducts
Bulk Material Handling
- Transfer chutes
- Hoppers
- Silos
- Conveyor liners
Construction Materials
- Wear-resistant components used in equipment handling abrasive raw materials
From machine to wear part — finished plates are cut, formed and fabricated into liners and wear components.
Applications of Finished Wear Plates
Bimetal and CCO wear plates produced on the JH-800K are fabricated into chute, hopper, crusher and conveyor liners, as well as transfer point and material handling components. Because the wear layer is metallurgically bonded rather than mechanically attached, the plate can be cut to shape and formed during subsequent fabrication.
Chute liners
Hopper liners
Crusher liners
Transfer point liners
Conveyor wear liners
Duct liners
Technical Specifications
Standard configuration of the JH-800K dual-torch four-wire wear plate hardfacing machine.
JH-800K — Main Technical Parameters
| Parameter | JH-800K Specification |
|---|---|
| Model | JH-800K |
| Machine Type | Dual-Torch Four-Wire Wear Plate Hardfacing Machine |
| Welding Width | ≤1550 mm |
| Welding Length | ≤3200 mm |
| Rapid Travel Speed | 0–9800 mm/min |
| Suitable Base Materials | Q235, Q345, low-carbon steel |
| Overlay Thickness | 2–20 mm |
| Hardfacing Speed | 100–300 mm/min |
| Torch Vertical Adjustment | 0–100 mm |
| Torch Height Adjustment | Manual mechanical adjustment |
| Oscillation Width | 10–60 mm |
| Linear Positioning Accuracy | ±1 mm / 5 m |
| Speed Error | ±2% |
| Main Control | Siemens PLC |
| HMI | 10.2-inch full-color touchscreen |
| Interface Language | Chinese / English |
| Welding Configuration | Dual torch / Four wire |
| Welding Modes | Straight-line / Grid / Oscillation |
| Operation | Automatic + Manual |
| Remote Control | Wireless handheld controller |
| Wire-Break Detection | Yes |
| Welding Position Recovery | Yes |
| Alloy Powder Feeding | Yes |
| Torch Cooling | Circulating water cooling |
| Base Plate Cooling | Variable-frequency circulating water cooling |
Operating Environment
| Requirement | Specification |
|---|---|
| Ambient Temperature | -10°C to +40°C |
| Relative Humidity | ≤95%, non-condensing |
| Workshop Environment | Well ventilated, without severe mechanical impact |
| Power Supply | 380 V ±10% * |
| Power Frequency | 50 Hz |
| Control Cabinet Input Power | 11.2 kW |
* Final voltage and electrical configuration should be confirmed according to the customer’s local industrial power supply before production.
Machine layout drawing — overall dimensions and floor space requirement.
JH-800K vs. Conventional Hardfacing Equipment
How the JH-800K platform compares with conventional or lower-automation hardfacing equipment.
| Capability | JH-800K | Conventional System |
|---|---|---|
| Welding Configuration | Dual torch / Four wire | Commonly single/dual wire |
| PLC Control | Siemens PLC | Basic PLC or manual |
| Motion Control | Servo-controlled | Basic motor control |
| Wire Feeding | Servo-controlled | Conventional feeding |
| Alloy Powder Addition | Automatic | Optional / manual |
| Overlay Thickness Control | Multi-mode servo control | Mainly travel-speed control |
| Welding Patterns | Straight / Grid / Oscillation | Usually straight welding |
| Oscillation | 10–60 mm | Limited or manual |
| Coordinate Display | Real-time | Often unavailable |
| Wire-Break Detection | Automatic | Often manual |
| Breakpoint Recovery | Supported | Manual repositioning |
| Torch Cooling | Circulating water | Basic cooling |
| Base Plate Cooling | Active circulating water | Often unavailable |
| Remote Control | Wireless | Usually local operation |
| HMI | 10.2" color touchscreen | Basic interface |
| Automatic Operation | One-button cycle | More operator intervention |
| Multi-Machine Supervision | Supported | More labor-intensive |
JH-800K vs. JH-800F
For customers comparing JINHUA wear plate hardfacing machines, the two models are designed with different priorities.
| Feature | JH-800K | JH-800F |
|---|---|---|
| Primary Positioning | Precision process control | High-capacity four-torch production |
| Welding Torches | 2 | 4 |
| Welding Wires | 4 | 4 |
| Max. Welding Width | 1550 mm | 1500 mm |
| Standard Welding Length | 3200 mm | 3000 mm |
| Overlay Thickness | 2–20 mm | 2–40 mm |
| PLC | Siemens | XINJE |
| Powder Feeding | Yes | Yes |
| Wire-Break Detection | Yes | — |
| Breakpoint Recovery | Yes | — |
| Base Plate Water Cooling | Yes | — |
| Welding Patterns | Straight / Grid / Oscillation | Bidirectional |
| Main Advantage | Process flexibility & automation | Parallel welding productivity |
Choose the JH-800K if you prioritize:
- Process control
- Servo wire feeding
- Alloy powder adjustment
- Plate deformation control
- Broken-wire monitoring
- Automated production management
- Different welding patterns
Choose the JH-800F if you prioritize:
- Four-torch simultaneous welding
- Higher parallel welding capacity
- Thick overlay production
- Simple high-output plate production
Not sure which model is suitable?
Send us your plate dimensions, overlay thickness and production target. Our engineers will recommend the appropriate configuration.
Who Should Choose the JH-800K?
The JH-800K is particularly suitable for:
- Chromium carbide overlay plate manufacturers
- Bimetal wear plate manufacturers
- Hardfacing workshops
- Wear liner manufacturers
- Mining wear-product suppliers
- Cement industry wear-part manufacturers
- Steel mill wear solution suppliers
- Companies establishing a new CCO plate production line
- Existing factories upgrading from manual hardfacing
- Manufacturers requiring more flexible alloy formulation
Custom Hardfacing Solutions
Every wear plate manufacturer has different requirements for base plate, overlay chemistry, hardness, overlay thickness, plate dimensions, welding consumables and production capacity.
JINHUA can customize the machine according to:
Plate Specifications
- Width
- Length
- Base plate thickness
- Overlay thickness
Welding Process
- Wire type
- Wire diameter
- Powder formulation
- Welding pattern
- Oscillation width
- Number of layers
Automation
- PLC configuration
- Servo control
- Cooling system
- Dust extraction
- Remote control
- Production monitoring
Electrical System
Machine voltage can be configured according to the industrial power standard of the destination country.
Tell Us Your Wear Plate Production Requirements
To recommend the correct machine and welding process, please provide the following information. Our engineering team can use this information to evaluate the welding process and recommend the machine configuration.
- 01 Base Plate MaterialExample: Q235 / Q345 / other steel grade
- 02 Base Plate ThicknessExample: 6 mm / 8 mm / 10 mm
- 03 Plate SizeWidth × length
- 04 Required Overlay ThicknessExample: 4 mm / 6 mm / 10 mm
- 05 Required Final Plate SpecificationExample: 6+4 mm / 8+6 mm / 10+10 mm
- 06 Required Overlay HardnessExample: HRC requirement
- 07 Required Alloy CompositionIf available
- 08 Welding Wire SpecificationWire type and diameter, if already determined
- 09 Required Production Capacitym²/day, plates/day or tons/month
- 10 Factory Power Supply
- 11 Destination Country
Request a Technical Proposal
Complete the form and our engineers will evaluate the welding process and recommend the machine configuration.
Frequently Asked Questions
Common questions from wear plate manufacturers evaluating automated hardfacing equipment.
What is the JH-800K wear plate hardfacing machine used for?
The JH-800K is designed for automatic overlay welding of wear-resistant alloy onto carbon steel plates.
It can be used to manufacture bimetallic wear plates and, with suitable welding consumables, chromium carbide overlay plates.
What does "dual-torch four-wire" mean?
The JH-800K uses two welding torches combined with a four-wire feeding configuration.
The system is designed to increase deposition capability while maintaining accurate control over wire feeding and the welding process.
What is the maximum plate size?
The standard machine supports a welding area of up to approximately 1550 mm × 3200 mm.
Customized configurations can be evaluated for special plate dimensions.
What overlay thickness can the JH-800K produce?
The specified overlay thickness range is approximately 2–20 mm.
Actual achievable thickness depends on welding consumables, number of layers and process parameters.
Can the machine produce chromium carbide overlay plates?
Yes. When suitable high-chromium hardfacing wire, alloy powder and welding parameters are used, the JH-800K can be applied to chromium carbide overlay plate production.
Final CCO plate chemistry and hardness depend on the consumables and process recipe rather than the machine alone.
Why does the machine use alloy powder?
Controlled powder addition allows additional alloying elements to be introduced into the weld deposit.
This provides manufacturers with greater flexibility to adjust alloy composition, carbide formation, hardness and wear performance.
How does the machine reduce plate deformation?
The JH-800K uses a circulating water cooling system for both the welding torch and the base plate.
The active base plate cooling system helps control excessive heat accumulation during continuous welding and therefore helps reduce thermal distortion.
What happens if the welding wire breaks?
The system includes wire-break detection and alarm functions.
The welding interruption position can be identified so that the operator can return to the interrupted location and complete the missing welding section.
Can the JH-800K perform oscillation welding?
Yes. The machine supports an oscillation range of approximately 10–60 mm and can perform straight-line, oscillation and grid welding.
Is the machine fully automatic?
The JH-800K supports automatic production cycles after the required welding parameters have been configured.
Manual operating modes are also provided for individual mechanism control, setup, maintenance and commissioning.
Can one operator control multiple machines?
Under standardized production conditions, multiple JH-800K units can be supervised by one trained operator.
The actual number depends on factory layout, loading/unloading method, production process and safety requirements.
Can JINHUA customize the machine?
Yes. Working dimensions, welding configuration, process parameters, electrical system, cooling, powder feeding and automation can be customized according to the customer’s production requirements.
Build a More Controlled Wear Plate Production Process
The quality of a wear plate does not depend only on welding power. Stable industrial production requires coordinated control of:
- Welding wire
- Alloy powder
- Deposition rate
- Travel speed
- Oscillation
- Heat input
- Cooling
- Welding trajectory
- Overlay thickness
- Alloy chemistry
One Automated Platform
The JH-800K Dual-Torch Four-Wire Wear Plate Hardfacing Machine integrates these functions into one automated platform to help manufacturers establish a more controlled, repeatable and scalable wear plate production process.
- Servo-controlled carriage and wire feeding
- Automatic alloy powder feeding
- Wire-break detection and breakpoint recovery
- Torch and base plate water cooling