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Hardox Steel

Hardox Steel

Hardox 500 plate

Novelty Structures Delivers High-Quality Hardox Steel Fabrications for

Superior Wear-Resistant Solutions in Demanding Applications

What is Hardox Steel?

Hardox Steel is a leading brand of wear-resistant steel, produced by the Swedish company SSAB. Thanks to its exceptional quality and market dominance, Hardox has become a generic term for wear-resistant plates worldwide.

Hardox steel offers high performance in aggressive applications and wear environments meaning that it is ideal for a variety of uses that other grades of steel simply cannot perform. This is due to Hardox’s ultra-hard surface, and high level of toughness of the material composition.

Construction and Earthmoving
- Bucket liners and blades for excavators and loaders
- Dump truck beds
- Crusher parts like jaws and hammers
Mining and Quarrying
- Chutes and hoppers for material handling
- Screens and feeders
- Drill rig components
Agriculture
- Plowshares and harrows
- Trailers for abrasive loads
- Cutter blades for harvesting
Recycling
- Shredder blades and hammers
- Recycling containers
- Conveyor liners
Transportation
- Dump trailers for higher payloads
- Abrasion-resistant shipping containers
- Rail car liners
Manufacturing
- Press tools like dies and punches
- Industrial mixer liners
- Pipes and elbows in slurry systems
Hardox Milling

Advantages of Hardox

  • Durability: Hardox Steel exhibits outstanding hardness and toughness, enduring extreme pressure in heavy industrial environments. Thanks to its durability, it outperforms carbon steel in impact absorption and withstanding wear and abrasion without permanent deformation.

  • Precision: Hardox Steel retains its shape even after getting exposed to harsh environments. It provides predictable and reliable performance while facilitating severely tight tolerances for thickness, flatness.

  • Fabrication: Hardox wear plate has a slightly different nature of metal fabrication. Drilling, countersinking, tapping, turning, and milling is performed with high-speed steel tools. The uniform properties, close thickness tolerances and smooth surface make Hardox® wear plate well suited to free bending and roll-forming. Hardox wear plate has great weldability to any type of weldable steel. Flatness and narrow thickness tolerances make automatic welding easy, and shorten the time for fit-up and tacking.

  • Longevity: Hardox steel is a more expensive material compared to the carbon steel but when you take their longevity into account, it is much more cost effective than mild steel.

  • Strength to Weight Ratio: Hardox steel offers a very high strength to weight ratio which essential for application where the weight of the material significantly contributes to the financial feasibility of the end product. Hardox wear plate cuts down on weight and extends the service life of steel structures in comparison to mild steel.

  • Versatility: The variety of dimensions makes Hardox wear plate suitable for a wide range of designs and products. The outstanding qualities of the flat Hardox wear plate grades are also available in the form of tubes and round bars.

  • Identification: All Hardox products are clearly marked. A unique identification number is stamped on the plates and sheets for traceability. Other data such as dimensions, serial number and heat number are printed before delivery. Knowing the product’s unique identity makes workshop processing and quality control much easier.

What makes Hardox ideal ?

For cost-sensitive and performance-oriented wearing applications, Hardox is the ideal option for the fabricators.

Hardox steel is frequently used in the plant engineering fabrications, bulk material handling structures and hoppers & chutes,

Although primarily intended as a wear plate, the unique combination of hardness and toughness allows it to perform as a load-carrying part in applications such as buckets, dump bodies and containers.

With Hardox steel, structures that are wear-resistant, strong and lightweight can be designed at the same time.

Hardox Steel Fabrication and machining

Manufacturing of Hardox Parts ?

  • Cutting

Hardox steel grades are suitable for all thermal cutting methods, including oxy-fuel cutting, plasma cutting and laser cutting. In some grades of hardox, preheating or post heating might be required in order to prevent cracking after cutting. Moreover, to overcome softening, submerged cutting is advised.

  • Bending

Metal Bending of high strength steel sheet and plate rarely proves to be difficult, however, there are certain parameters that must be considered.

  • Welding

For a high-quality welding, clean the weld area to remove dust, oil, corrosion or any impurities prior to welding. In addition to good welding hygiene, make especially sure you consider the following aspects;

  • Preheating

It is essential to follow the recommended minimum preheating temperature as well as the procedure for obtaining and measuring the temperature around the joint to avoid hydrogen cracking.

  • Heat input

Various welding processes have different thermal efficiency. Excessive heat input increases the width of the heat affected zone impairing the mechanical properties and the wear resistance. Welding with low heat input provides major benefits.

  • Weld sequence

Before tack welding, it is essential to maintain a root opening not more than 3 mm. A uniform gap size along the joint is desired. Moreover, it is recommended to avoid weld start and weld stops in highly stressed areas.

  • Welding Consumables

Unalloyed and low-alloyed consumables with a maximum yield strength of 500 MPa are generally recommended for Hardox steel. Low-alloyed consumables result in higher hardness of the work piece which can reduce the wear rate of the weld metal.

Bending Hardox

Bending Hardox

  • Check the rolling direction of the plate. If possible, orient the rolling direction perpendicular to the bend line. The plate can often be bent tighter this way.

  • Check the surface quality of the plate. Uneven surfaces or impurities on the surface may affect bendability as it can cause of fractures

  • Grind the thermal cut and sheared edges.

  • The bending tools should be harder than the work piece for the longevity of the tool life.

  • Avoid re-bending to correct the profile angle. Bending the same place significantly reduces the bendability

  • It is not possible accurately predict the spring back of a material when bending, since this depends to multiple factors. That is why trial bending is recommended

  • The strong force applied to the high-strength steel plate can lead to cracks on the surface, therefore, it is important to ensure the bending radius is adequately large based on the work piece thickness.

Comparison of Hardox Grades

Challanges of Hardox Fabrication

  • Thermal Cutting: Plasma and laser cutting can generate heat-affected zones (HAZ), potentially reducing the hardness along the cut edges.
  • Crack Sensitivity: Hardox is prone to cold cracking if improper welding techniques are used. Preheating may be necessary for thicker plates (over 20 mm) or highly constrained welds.
  • Heat Input Management: Excessive heat during welding can soften the material and degrade its wear resistance.

 

  • Springback: Due to its high strength, Hardox has a significant springback tendency, requiring adjustments during bending to achieve the desired angle.
  • Cracking Risk: If the minimum recommended bend radius is not followed, cracking can occur along the bend line.
  • Tool Wear: Tools used for forming Hardox can wear out faster than with regular steel, increasing maintenance and tooling costs.

 

  • Tool Wear: Hardox’s hardness accelerates wear on cutting tools, necessitating frequent replacements or the use of carbide-tipped or coated tools.

 

Comparison of Hardox Grades   

Welding Hardox

  • Preheating

Preheating helps prevent hydrogen-induced cracking and improves weldability. No Preheating is required for Hardox 400/450 (up to 20mm thickness) under normal conditions. Preheating is essential when welding Hardox® steel in specific conditions, such as for Hardox 500 and higher grades, plates thicker than 20mm, or when working in cold environments or areas with moisture. The recommended preheat temperature ranges between 150–200°C (300–400°F), depending on the grade and thickness of the steel.

  • Filler Materials

It is advised to use unalloyed or low-alloyed welding consumables with a maximum yield strength of 500 MPa, while higher-strength consumables (up to 900 MPa) are appropriate for Hardox 400 and 450 in thicknesses ranging from 0.7 to 6.0 mm. Low-alloyed consumables enhance weld metal hardness, helping to reduce wear rates, and hard facing consumables can be applied to the top cap of joints for better wear resistance. To ensure proper weld quality, hydrogen content in the weld metal must not exceed 5 ml/100 g, which can be achieved using solid wire in MAG/GMA or TIG/GTA welding. Proper storage of consumables as per manufacturer instructions helps maintain these standards.

  • Welding on Hardox Primer

Hardox wear plate can be welded directly on its low-zinc primer, which can also be brushed or ground off around the joint if needed. Removing the primer before welding helps reduce weld porosity and improves out-of-position welding. If the primer remains, surface and subsurface porosity may increase slightly. Using FCAW with basic flux minimizes porosity. Proper ventilation is essential to mitigate potential health and environmental risks from the primer during welding.

Hardox Preheating Temperatures
Hardox Preheating Temperatures
Hardox Grade Preheating Temperature
Hardox® HiTemp 300°C (572°F)
Hardox® HiTuf 300°C (572°F)
Hardox® HiAce 225°C (437°F)
Hardox® 400 225°C (437°F)
Hardox® 450 225°C (437°F)
Hardox® 500 225°C (437°F)
Hardox® 500 Tuf 225°C (437°F)
Hardox® 550 225°C (437°F)
Hardox® 600 225°C (437°F)
Hardox® Extreme 100°C (212°F)

Machining Hardox

Machining Hardox wear plates requires high-quality carbide tools and precise parameters, with low cutting speeds and high feed rates to minimize heat and tool wear. Using techniques like peck drilling, climb milling, and ceramic or CBN inserts helps manage cutting forces and improve surface finish.

  • Drilling

For Drilling Hardox Plates, HSS drills should only be used in unstable machine conditions and are suitable for materials up to 500 Brinell.

For stable conditions, solid cemented carbide drills, exchangeable head drills, or indexable insert drills are preferred. To reduce vibrations and extend drill life, minimize the distance to the column, avoid using overly long drills, securely clamp the workpiece, use a firm table, apply 8-12% coolant, and momentarily reduce the feed rate just before breakthrough to prevent drill tip damage.

Hardox Drilling Data
Hardox Grades Drilling Parameters
Steel Grade Cutting Speed (Vc), m/min Feed per Revolution (fn) mm/rev
Ø 10 mm Ø 15 mm Ø 20 mm Ø 25 mm Ø 30 mm
Hardox HiTemp 7 – 9 0.11 0.16 0.23 0.29 0.35
Hardox HiAce 5 – 7 0.1 0.15 0.2 0.25 0.3
Hardox HiTuf 10 – 12 0.1 0.16 0.23 0.29 0.35
Hardox 400 7 – 9 0.11 0.16 0.23 0.29 0.35
Hardox 450 5 – 7 0.1 0.15 0.2 0.25 0.3
Hardox 500 3 – 5 0.08 0.12 0.16 0.2 0.24
Hardox 500 Tuf 3 – 5 0.08 0.12 0.16 0.2 0.2
  • Tapping and Thread Milling

For tapping materials up to 500 Brinell, it is recommended to use four-flute taps designed to handle high torque. If the diameter is not critical, drilling the hole 3% larger than standard can help extend the tap’s lifespan.

 

Tapping Speeds for Hardox Grades
Steel Grade Cutting Speed (Vc), m/min Size from – to
Hardox HiTemp 4 – 8 M6 – M30
Hardox HiAce 1 – 3 M8 – M30
Hardox HiTuf 6 – 10 M6 – M30
Hardox 400 4 – 8 M6 – M30
Hardox 450 1 – 5 M6 – M30
Hardox 500 1 – 3 M8 – M30
Hardox 500 Tuf 1 – 3 M8 – M30

 

For threadmilling, a CNC machine is necessary.

 

Threadmilling Speeds for Hardox Grades
Steel Grade Cutting Speed (Vc), m/min Feed per Tooth (fz), mm/tooth
Hardox HiTemp 60 – 80 0.02 – 0.05
Hardox HiAce 40 – 60 0.02 – 0.04
Hardox HiTuf 70 – 100 0.03 – 0.06
Hardox 400 60 – 80 0.02 – 0.05
Hardox 450 50 – 70 0.02 – 0.05
Hardox 500 40 – 60 0.02 – 0.05
Hardox 500 Tuf 40 – 60 0.02 – 0.05
Hardox 550 35 – 55 0.02 – 0.04
Hardox 600 30 – 40 0.01 – 0.03
Hardox Extreme 25 – 35 0.01 – 0.03
  • Milling

To achieve a thicker chip, the milling cutter should be positioned off the centre. Cutting through the center line of the cutter might cause vibration. Proper clamping is also essential to prevent vibration. If insert is used, dry milling is recommended.

Hardox Face Milling Parameters
Steel Grade Cutting Speed (Vc), m/min Feed per Tooth (fz), mm/t
Min Max
Hardox HiTemp 120 – 160 0.1 0.25
Hardox HiAce 100 – 140 * 0.10 * 0.25
Hardox HiTuf 140 – 180 0.1 0.25
Hardox 400 120 – 160 0.1 0.25
Hardox 450 110 – 150 0.1 0.25
Hardox 500 100 – 140 0.1 0.25
Hardox 500 Tuf 100 – 140 0.1 0.25
Hardox 550 70 – 90 0.1 0.2
Hardox 600 50 – 70 0.1 0.2
Hardox Extreme 30 – 50 0.1 0.2
  • Turning

Cutting fluid is highly recommended in turning Hardox bars. For large work pieces, tougher carbide grade would be required. For higher Feed rates, lower the cutting speed should set.

Recommended Turning Parameters for Hardox Bars
Cuttingdata
Turning		 Cemented Carbide
Roughing Finishing
Cutting speed, Vc (m/min) 70 – 90 70 – 130
Feed per revolution, fn (mm/r) 0.2 – 0.6 0.05 – 0.3
Cutting depth, ap (mm) 2 – 4 0.5 – 2
Suitable grades P20 – P35*
K20 – K30* / K01 – K20*

How can we help you ?

Hardox Steel is indispensable to various applications and their success depends on the careful selection of contractors

Novelty Structures stands out as a reliable partner in providing high-quality Hardox Steel Fabrications and Part Manufacturing tailored to demanding industrial needs.

Contact our team to further discuss your needs.

FAQ

What makes Hardox steel unique?2024-12-25T00:52:11+00:00

Hardox steel combines hardness, toughness, and flexibility, making it ideal for heavy-duty applications. It resists wear, handles impact without cracking, and can be machined, cut, or welded like regular steel.

How do I choose the right grade of Hardox steel?2024-12-25T00:52:45+00:00

The choice of grade depends on your specific application:

  • For general wear resistance, choose Hardox 400 or 450.
  • For extreme wear conditions, opt for Hardox 500 or 600.
  • For structural components under heavy impact, Hardox HiTuf is ideal.
What thicknesses are available for Hardox steel?2024-12-25T00:53:19+00:00

Hardox steel is available in a wide range of thicknesses, from 2 mm (for lightweight applications) to over 100 mm (for heavy-duty uses).

How does Hardox compare to standard steel?2024-12-25T00:53:54+00:00

Hardox steel offers superior hardness, toughness, and wear resistance compared to standard steel. This means longer service life, reduced maintenance, and better performance under challenging conditions.

Can Hardox steel be customized for specific projects?2024-12-25T00:54:43+00:00

Yes! Hardox steel can be customized through cutting, machining, and processing to meet your unique requirements.

What is the delivery time for Hardox steel?2024-12-25T00:55:15+00:00

Delivery time depends on the grade, thickness and dimensions

Why should I choose Hardox over other wear-resistant steels?2024-12-25T00:55:58+00:00

Hardox steel stands out because of its consistent quality, proven durability, and versatility.

How is Hardox Steel manufactured?2024-12-25T00:56:43+00:00

Hardox steel is produced through a controlled rolling process, which results in a fine-grained microstructure. This microstructure contributes to its exceptional wear resistance and toughness.

Does Hardox steel work in cold climates?2024-12-25T00:57:19+00:00

Yes, Hardox steel maintains its toughness and impact resistance even in very low temperatures, making it suitable for cold environments like Arctic mining operations.

Can I use standard tools to process Hardox steel?2024-12-25T00:57:52+00:00

High-strength tools are recommended:

  • Drilling and Milling: Use carbide or cobalt-tipped tools.
  • Cutting: Plasma, laser, or oxy-fuel methods are most efficient.
  • Forming: Requires proper equipment and following bending guidelines for optimal results.
Is Hardox steel resistant to corrosion?2024-12-25T00:58:21+00:00

While Hardox steel is primarily designed for wear resistance, it can be treated with protective coatings to enhance its resistance to corrosion, especially in environments with high moisture or chemicals.

Hardox steel fabrication - bending

Knowledge Hub

Attachments
Comparison of Hardox Grades
Common Weld Defects

Novelty Steel offers Turkish steel fabrication solutions to various industries with broad scope of applications.

For all inquiries please contact : info@noveltystructures.com

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