Dual-Torch Gantry Open-Arc / Submerged-Arc Wear Plate Hardfacing Machine
Flexible automated hardfacing for open-arc and submerged-arc wear plate production.
JINHUA’s Dual-Torch Gantry Wear Plate Hardfacing Machine is an automated overlay welding system developed for industrial production of wear-resistant composite plates.
The equipment is available in open-arc hardfacing and submerged-arc hardfacing configurations, allowing the welding process to be selected according to the required wear plate structure, consumables, surface characteristics and production process.
Dual-Torch Gantry Platform Capabilities
Built around a rigid gantry platform, the machine integrates dual welding torches, CNC X/Y/Z motion control, TECO servo gantry drive, digital PLC control, automatic welding path calculation, dual-drive wire feeding, water-cooled hardfacing torches, active base plate water cooling, integrated fume extraction for open-arc operation, a 10.2-inch touchscreen HMI, wireless remote control and the HM-1250 digital hardfacing power source.
What Is This Dual-Torch Wear Plate Hardfacing Machine?
This equipment is an automated gantry welding system designed to deposit wear-resistant alloy onto a carbon steel base plate.
During production, the machine coordinates:
- Welding torch movement
- Wire feeding
- Welding current
- Travel speed
- X/Y position
- Z-axis torch height
- Welding trajectory
- Base plate cooling
- Torch cooling
The deposited alloy forms a metallurgically bonded wear-resistant layer over the structural steel substrate.
Depending on the welding consumables and selected process, the machine can be used for manufacturing:
Bimetallic wear plates
Hardfaced wear plates
Chromium carbide overlay plates
CCO wear plates
Smooth-surface overlay plates
Customized alloy overlay plates
The equipment is particularly suitable for manufacturers requiring an automated platform that can be configured around different hardfacing processes.
Gantry hardfacing platform — dual torches, CNC X/Y/Z motion, active plate cooling and integrated fume extraction.
Open-arc hardfacing in progress — the welding arc operates without being covered by a granular flux blanket.
Open-Arc or Submerged-Arc Hardfacing?
One of the main advantages of this machine family is the availability of different welding process configurations.
Open-Arc Configuration
Open-arc hardfacing is commonly used for automated production of conventional chromium carbide overlay wear plates. The welding arc operates without being completely covered by a granular flux blanket.
With suitable self-shielded flux-cored hardfacing wire, the process can provide high-efficiency deposition for industrial CCO plate production.
Open-arc configurations are particularly suitable when the customer requires:
- Conventional CCO wear plate production
- Flux-cored hardfacing wire
- Flexible automatic welding
- Visible welding process
- Straight or programmed overlay paths
- High-volume wear plate production
Submerged-Arc Configuration
In submerged-arc welding, the welding arc operates beneath a layer of granular flux. The wire electrode is continuously fed into the welding area while the flux protects the molten weld pool and participates in the welding process.
A submerged-arc configuration can be considered when the production process requires:
- Flux-covered automatic welding
- Stable mechanized welding
- High-current operation
- Controlled weld deposition
- Smooth overlay requirements
- Customized alloy surfacing processes
One platform, two process configurations — open-arc and submerged-arc hardfacing on the same gantry structure.
Selecting the Process
The appropriate process should be selected according to the required finished plate properties rather than simply choosing between open arc and submerged arc based on machine speed.
Not sure which process is suitable? Send us your target plate specification, alloy composition and required hardness. JINHUA engineers can evaluate whether open-arc or submerged-arc hardfacing is more appropriate.
Which Hardfacing Process Should I Choose?
The correct process depends on the finished wear plate you intend to manufacture.
Open-Arc vs. Submerged-Arc Configuration
| Requirement | Open-Arc Configuration | Submerged-Arc Configuration | |
|---|---|---|---|
| Typical Process | Open arc / self-shielded hardfacing | Flux-covered submerged arc | |
| Common Application | Conventional CCO wear plate | Alloy surfacing / smooth overlay applications | |
| Arc Visibility | Visible | Arc covered by flux | |
| Consumable System | Hardfacing wire | Wire + welding flux | |
| Process Automation | High | High | |
| Multi-Torch Capability | Yes | Yes, depending on configuration | |
| Flat Plate Production | Yes | Yes | |
| Automatic Path Control | Yes | Yes | |
| Water-Cooled Platform | Yes | Yes | |
| Best Selection Based On | Alloy, hardness, plate structure and production target | Alloy, surface requirement and welding procedure |
Why Use a Dual-Torch Gantry Hardfacing System?
Higher welding coverage with controlled motion. The machine uses two independent hardfacing torches mounted on a rigid gantry structure.
Compared with a conventional single-torch machine, the dual-torch configuration increases the effective welding coverage during production.
At the same time, CNC-controlled movement helps maintain consistent:
- Welding trajectories
- Bead spacing
- Welding speed
- Torch position
- Overlay coverage
The result is a production platform designed for continuous manufacture rather than operator-dependent manual hardfacing.
Dual-torch gantry configuration — two independent torches on a rigid gantry structure.
Submerged-arc hardfacing — the arc operates beneath a layer of granular flux.
HM-1250 Digital Hardfacing Power Source
The machine can be equipped with the HM-1250 inverter digital hardfacing welding power supply. The power source is developed for high-current overlay welding and uses Infineon IGBT power components.
The system is designed to provide:
- Stable high-current output
- Continuous hardfacing capability
- Arc stability
- Digital welding control
- Strong electrical interference resistance
The final power source configuration should be selected according to:
Open-arc or submerged-arc process
Welding wire diameter
Required welding current
Deposition rate
Alloy system
Plate specification
HM-1250 digital hardfacing power source — Infineon IGBT power components for high-current overlay welding.
TECO PLC control cabinet & 10.2″ touchscreen HMI — centralized control of motion, welding parameters and alarms.
Typical Production Process
The machine performs the selected welding program automatically, from plate loading to the finished wear plate.
Load the Base Plate
Place the Q235, Q345 or suitable low-carbon steel plate onto the fixed welding platform.
Clamp the Plate
Secure the base plate using the mechanical clamping system.
Start Cooling
Activate the circulating water cooling system and set the appropriate water pressure.
Prepare Welding Consumables
Load the required welding wire. For submerged-arc configurations, prepare the appropriate welding flux according to the qualified welding procedure.
Enter Production Parameters
- Welding width
- Welding length
- Welding speed
- Welding trajectory
- Torch position
- Related process parameters
Automatic Path Calculation
The PLC calculates the required hardfacing trajectory.
Position the Dual Torches
The CNC motion system moves the welding torches to the programmed starting positions.
Start Automatic Hardfacing
The machine performs the selected welding program.
Monitor the Process
Operators monitor the machine status and welding path through the touchscreen.
Complete the Wear Plate
After welding and controlled cooling, the finished plate can proceed to leveling, cutting, bending, rolling or fabrication according to the final application.
Machine Details
Gantry frame, torch carriage, wire feeding, cooling platform, clamping system and control cabinet of the standard dual-torch gantry platform.
Gantry structure — left and right columns with an upper crossbeam and CNC torch slides.
Machine configuration — standard dual-torch gantry build.
Welding platform — fixed table with clamping and circulating water cooling.
Motion & transmission components — servo drive, reducers and rack-and-pinion gantry movement.
Production setup — machine prepared for continuous wear plate hardfacing.
Dual-drive wire feeding & straightener — two driven feed rollers with integrated wire straightening.
What Wear Plates Can Be Produced?
Depending on the welding consumables and the selected open-arc or submerged-arc process, the platform can be configured for several overlay plate types.
Chromium Carbide Overlay Plate
CCO plate produced with suitable chromium carbide hardfacing wire and welding parameters.
Bimetallic Wear Plate
structural steel base plate plus wear-resistant alloy overlay.
Smooth Overlay Plate
evaluated for a smoother deposited surface with a flux-covered automated overlay process.
Chromium Carbide Overlay Plate
With suitable chromium carbide hardfacing wire and welding parameters, the machine can be used to produce chromium carbide overlay plate, commonly called:
CCO plate / Chromium carbide wear plate / Chromium carbide clad plate / Bimetal wear plate
Bimetallic Wear Plate
The finished plate combines:
Structural Steel Base Plate + Wear-Resistant Alloy Overlay
The steel substrate provides structural support and fabrication capability while the hardfacing layer provides wear resistance.
Smooth Overlay Plate
A submerged-arc hardfacing configuration can also be evaluated for customers requiring a smoother deposited surface and a flux-covered automated overlay process.
Final surface condition depends on:
Welding process / Welding wire / Flux / Alloy chemistry / Welding current / Travel speed / Number of layers
Customized Alloy Overlay Plate
Different welding wire and flux combinations can be evaluated according to the required:
Hardness / Carbide system / Abrasion resistance / Impact resistance / Surface characteristics / Service environment
Typical Applications
Finished wear-resistant plates can be fabricated into components for severe abrasive environments.
Mining
- Chute liners
- Hopper liners
- Crusher liners
- Transfer points
- Conveyor liners
Cement
- Raw material chutes
- Separator components
- Grinding system liners
- Duct liners
- Material handling components
Steel Industry
- Sintering equipment
- Raw material systems
- Conveyor components
- Wear-resistant liners
Power Industry
- Coal handling equipment
- Ash handling systems
- Wear-resistant ducts
- Transfer chutes
Bulk Material Handling
- Hoppers
- Silos
- Conveyors
- Transfer systems
Heavy Industrial Fabrication
- Wear-resistant components manufactured from overlay plate for abrasive service conditions
Technical Specifications
Standard configuration of the dual-torch gantry open-arc / submerged-arc wear plate hardfacing machine.
Main Technical Parameters
| Parameter | Specification |
|---|---|
| Machine Type | Dual-Torch Gantry Wear Plate Hardfacing Machine |
| Welding Process | Open-Arc / Submerged-Arc configuration |
| Welding Torches | 2 |
| Mechanical Structure | Gantry Type |
| Welding Width | ≤1510 mm |
| Welding Length | ≤3000 mm |
| Rapid Travel Speed | 0–9800 mm/min |
| Suitable Base Materials | Q235, Q345, low-carbon steel |
| Overlay Thickness | 3–20 mm |
| Hardfacing Speed | 50–500 mm/min |
| Torch Vertical Travel | 0–200 mm |
| Torch Height Adjustment | Digital / CNC Control |
| Linear Positioning Accuracy | ±0.1 mm / 5 m* |
| Speed Error | ±2% |
| X/Y Motion | Servo-controlled |
| Gantry Servo | TECO |
| Z-Axis Control | Stepper-controlled CNC lifting |
| HMI | 10.2-inch full-color touchscreen |
| Welding Patterns | Straight / W-Pattern / Wave |
| Wireless Remote | Yes |
| Torch Cooling | Circulating Water |
| Base Plate Cooling | Variable-Frequency Circulating Water |
| Wire Feeding | Dual-Drive |
| Wire Straightening | Integrated |
| Maximum Specified Wire Extension | Up to 40 mm |
| Welding Power Source | HM-1250 Hardfacing Power Supply |
* Positioning accuracy should be confirmed against the actual machine inspection record before publication.
Main Machine Configuration
The system mainly consists of:
- Gantry positioning frame
- Fixed welding platform
- Dual hardfacing torches
- Vertical torch adjustment slides
- Horizontal torch adjustment slides
- CNC lifting slides
- X/Y servo motion system
- Z-axis lifting system
- Dual-drive wire feeders
- Wire straightening units
- Welding wire support system
- Water-cooled welding torches
- Base plate circulating water cooling system
- Plate clamping system
- Fume extraction system
- Integrated electrical cabinet
- 10.2-inch touchscreen control panel
- Wireless remote controller
- HM-1250 hardfacing power source
- Flux handling system where required for submerged-arc configuration
Machine layout drawing — overall dimensions, gantry span and floor space requirement.
Dual-Torch Open-Arc / Submerged-Arc Machine vs. JH-700
Although both machines use a gantry-type design, they target different production requirements.
| Feature | Dual-Torch Open/SAW Machine | JH-700 |
|---|---|---|
| Main Positioning | Process flexibility | Four-torch gantry productivity |
| Welding Torches | 2 | 4 |
| Open-Arc Configuration | Yes | Primarily hardfacing configuration |
| Submerged-Arc Configuration | Available | Not primary positioning |
| Welding Width | ≤1510 mm | ≤1550 mm |
| Welding Length | ≤3000 mm | ≤3200 mm |
| Overlay Thickness | 3–20 mm | 2–20 mm |
| Hardfacing Speed | 50–500 mm/min | 100–300 mm/min |
| Gantry Structure | Yes | Yes |
| CNC X/Y/Z | Yes | Yes |
| Base Plate Cooling | Yes | Yes |
| Welding Patterns | Straight / W / Wave | Straight / W / Wave |
| Welding Power | HM-1250 configuration | JHM-650 configuration |
| Main Advantage | Open-arc / submerged-arc process choice | Four-torch production capacity |
Choose the Dual-Torch Open/SAW Machine if you prioritize:
- Open-arc process
- Submerged-arc process
- Process flexibility
- Higher-current hardfacing
- Wider welding speed adjustment
- Specialized alloy overlay production
- Dual-torch automated welding
Choose the JH-700 if you prioritize:
- Four-torch production
- Larger welding coverage
- High-volume conventional wear plate production
- Gantry-based multi-torch automation
Comparison with Other JINHUA Flat Plate Hardfacing Machines
Each series is positioned around a different welding process and production objective.
| Model / Series | Core Advantage |
|---|---|
| Dual-Torch Open/SAW Gantry | Open-arc & submerged-arc process flexibility |
| JH-700 | Four-torch CNC gantry hardfacing |
| JH-800F | Four-torch high-productivity bidirectional welding |
| JH-800K | Dual-torch four-wire precision process control |
This product structure allows customers to select equipment based on the welding process and production objective, rather than simply comparing the number of welding torches.
Who Should Choose This Machine?
The machine is suitable for:
- Wear plate manufacturers
- CCO plate manufacturers
- Smooth overlay plate manufacturers
- Bimetal wear plate factories
- Hardfacing workshops
- Mining wear-product manufacturers
- Cement industry wear-part suppliers
- Steel mill wear solution companies
- Welding consumable manufacturers developing overlay plates
- Companies establishing a new wear plate production facility
- Factories requiring both conventional and specialized alloy hardfacing solutions
Customized configurations — non-standard machine builds.
On-site commissioning — installation, commissioning and operator training.
Customized Hardfacing Solutions
JINHUA can configure the machine according to the customer’s production requirements.
Welding Process
- Open arc
- Submerged arc
- Welding wire selection
- Welding flux selection
- Customized alloy process
Plate Dimensions
- Welding width
- Welding length
- Base plate thickness
- Overlay thickness
Automation
- PLC control
- CNC axis movement
- HMI
- Remote control
- Industrial communication
Cooling
- Platform cooling
- Water pressure
- Cooling capacity
- Circulation control
Workshop Integration
- Fume extraction
- Flux handling
- Plate loading
- Plate unloading
- Production line integration
Tell Us Your Wear Plate Requirements
To determine whether an open-arc or submerged-arc configuration is more suitable, please provide the following information. If you have not yet selected the welding process, send us the finished plate requirements instead — JINHUA engineers can evaluate the process and recommend an appropriate configuration.
- 01 Finished Plate TypeCCO / smooth overlay / customized alloy plate
- 02 Base Plate MaterialQ235 / Q345 / other steel grade
- 03 Base Plate ThicknessExample: 6 mm / 8 mm / 10 mm
- 04 Plate DimensionsWidth × length
- 05 Required Overlay ThicknessExample: 3 mm / 6 mm / 10 mm
- 06 Final Plate SpecificationExample: 6+4 mm / 8+6 mm / 10+10 mm
- 07 Required HardnessHRC requirement
- 08 Required Alloy CompositionIf available
- 09 Welding Wire Type and DiameterIf already determined
- 10 Preferred Welding ProcessOpen arc / submerged arc / not yet determined
- 11 Required Production Capacitym²/day, plates/day or tons/month
- 12 Factory Power Supply
- 13 Destination Country
Request a Technical Proposal
Complete the form and our engineers will evaluate whether open-arc or submerged-arc hardfacing is more appropriate for your plate.
Frequently Asked Questions
Common questions about open-arc and submerged-arc wear plate hardfacing.
What is the difference between open-arc and submerged-arc hardfacing?
In open-arc hardfacing, the welding arc is exposed during operation and is commonly used with self-shielded flux-cored hardfacing wire.
In submerged-arc welding, the arc operates underneath a granular flux layer. The correct process depends on the required overlay chemistry, surface condition, deposition characteristics and finished plate specification.
Can one machine produce both open-arc and submerged-arc wear plates?
JINHUA offers the platform in different process configurations.
Whether a specific machine can be converted between open-arc and submerged-arc operation depends on its welding power source, torch, wire feeding, flux handling and process configuration. Please confirm the required processes before final technical design.
Which process is better for chromium carbide overlay plate?
Open-arc hardfacing is widely used for conventional CCO plate manufacturing.
However, the final process should be selected according to the required hardness, alloy chemistry, surface quality and production requirements.
When should I consider submerged-arc hardfacing?
Submerged-arc configuration can be considered when the required overlay process uses a wire-and-flux combination and the customer requires a fully mechanized flux-covered welding process.
Our engineers can evaluate the application based on the finished plate specification.
What is the maximum plate size?
The standard welding area is approximately 1510 mm × 3000 mm. Customized dimensions can be evaluated.
What overlay thickness can the machine produce?
The specified standard overlay thickness range is approximately 3–20 mm.
Actual achievable thickness depends on the welding process, number of layers and consumables.
What is the hardfacing speed?
The standard specified welding speed range is 50–500 mm/min.
Actual production speed depends on welding current, wire diameter, overlay thickness, welding pattern and process requirements.
Why is the working platform water cooled?
Continuous overlay welding introduces significant heat into the base plate. Circulating water cooling helps control heat accumulation and reduce thermal deformation during production.
What welding patterns are available?
The machine supports straight-line welding, W-pattern welding and wave-pattern welding. Additional trajectories can be evaluated for customized applications.
Can welding parameters be stored?
Yes. The PLC-based digital control system can store process settings for repeat production.
Does the machine automatically calculate the welding path?
Yes. After the operator enters the required welding dimensions and process parameters, the system calculates the corresponding welding trajectory.
Does the machine support flux-cored wire?
Yes. The dual-drive wire feeding mechanism is designed for stable feeding of industrial hardfacing wires, including suitable flux-cored welding wires.
Final wire compatibility should be confirmed according to diameter and process requirements.
Is fume extraction included?
The open-arc configuration can be equipped with torch-side fume extraction ducts connected to a centralized extraction system.
Final workshop ventilation should comply with local occupational health and safety requirements.
Can the machine be customized?
Yes. JINHUA can customize the working area, welding process, welding power, wire feeding, flux handling, cooling, motion control, electrical configuration, fume extraction and automation level according to the customer’s production requirements.
One Platform for Different Wear Plate Hardfacing Processes
A wear plate production machine should not be selected only by welding speed or number of torches. The correct system depends on the relationship between:
- Welding process
- Welding wire
- Flux
- Welding current
- Deposition rate
- Dilution
- Alloy chemistry
- Overlay thickness
- Surface requirement
- Cooling
- Production capacity
Open-Arc / Submerged-Arc Flexibility
JINHUA’s Dual-Torch Gantry Open-Arc / Submerged-Arc Wear Plate Hardfacing Machine provides an automated platform for manufacturers requiring controlled multi-axis welding and flexible hardfacing process configurations.