When should you use Manganese Steel and when should you switch to Chromium Carbide Overlay (CCO) Plates? Here’s your complete comparison guide.
Introduction: The Two Giants in Wear Resistance
Wear protection is crucial in high-abrasion environments like mining, cement, recycling, power plants, and crushers. Two of the most used materials are:
- High Manganese Steel (Hadfield/X120Mn12)
- Chromium Carbide Overlay Plates (CCO)
While both resist wear, their core strength lies in different mechanisms—Manganese excels in impact; CCO rules in abrasion. Let’s break it down.
Technical Comparison: Manganese Steel vs CCO
| Property | Manganese Steel | Chromium Carbide Overlay Plate |
|---|---|---|
| Wear Resistance | Moderate (improves under impact) | Very High (especially sliding abrasion) |
| Hardness | 200–500 BHN (after work-hardening) | 550–700+ BHN |
| Impact Resistance | Excellent | Poor to Moderate |
| Application Type | High-impact zones | High-abrasion, low-impact zones |
| Welding & Fabrication | Difficult, requires special electrodes | Can be cut and formed with care |
| Weight | Dense | Lighter (due to cladding) |
| Life Span | Medium to High (if used correctly) | Extremely High in abrasion zones |
Where Manganese Steel Performs Best
- Jaw crusher liners
- Cone crusher mantles
- Rail crossing points
- Bulldozer blades
- Impact hammers
Manganese Steel shines when shock absorption, crack resistance, and work-hardening are needed.
Where CCO Plates Dominate
- Coal chute liners
- Duct elbows
- Cement kiln components
- Cyclones and hoppers
- Slurry pipelines
CCO Plates are unbeatable when sliding wear is the enemy, especially in cement, power, and coal handling industries.
Key Differences in Real-World Applications
- In jaw crushers, Manganese self-hardens from repeated impact—ideal for raw stone crushing.
- In hoppers and conveyors, CCO lasts 3x longer because abrasion happens without significant impact.
Don’t use CCO where impact is frequent—the brittle overlay may crack.
Expert Insight: Why Selection Matters
According to multiple wear plate specialists (source, source), the number one mistake buyers make is using CCO where impact loads exist or using manganese in sliding abrasion.
Each plate must be applied correctly:
- Manganese Steel → Impact + Compression
- CCO Plate → Abrasion + Flow
Voice Search Optimized FAQs
1. Is manganese steel better than chromium carbide?
Not always. Manganese is better for impact zones; CCO is better for sliding abrasion zones.
2. Can CCO replace manganese steel in crushers?
No. CCO cracks under impact. Use manganese in jaws, mantles, and crushers
3. Which is more wear-resistant: manganese or CCO?
CCO has higher wear resistance, but only in low-impact applications.
4. How long does a CCO plate last?
It can last 3–5x longer than mild steel in high abrasion environments.
5. Can manganese steel be used in cement plants?
Yes, for impact areas like hammers. But for chutes and ducts, use CCO.
Summary Table: Application-Based Usage
| Application | Recommended Plate |
|---|---|
| Jaw Crushers | Manganese Steel |
| Chutes in Cement | CCO Plate |
| Crusher Mantles | Manganese Steel |
| Slurry Pipes | CCO Plate |
| Impact Hammers | Manganese Steel |
| Duct Bends | CCO Plate |
When to Combine Both?
Smart fabricators use Manganese inside crushers and CCO downstream in chutes, bins, or cyclones. This hybrid approach maximizes uptime and reduces total cost of ownership.