AR400 & AR500 Abrasion Resistant Wear Plate Canadian Fabrication Specs
Complete technical specification for AR400 and AR500 abrasion resistant steel plate used in Canadian heavy fabrication, mining, and wear-part manufacturing. Includes Brinell hardness ranges, standard stock sizes from Canadian service centres, machinability ratings, common defects, and storage guidelines for plate up to 2" thick.
Material Overview & Common Uses
AR400 and AR500 are quenched and tempered, through-hardened abrasion resistant (AR) steel plates designed for high-wear environments. AR400 offers a nominal Brinell hardness of 360–440 HBW, while AR500 targets 460–540 HBW. Both grades are widely stocked by Canadian service centres (e.g., Russel Metals, Samuel, Nova Steel) in standard widths of 48", 60", 72", 96", and 120", with lengths up to 480". Common thicknesses range from 3/16" (4.76 mm) to 2" (50.8 mm). Typical applications include: dump truck liners, bucket wear plates, chute liners, crusher components, conveyor skirting, and heavy equipment cutting edges. In Canadian fabrication shops, these plates are often used for custom wear parts in mining, forestry, and aggregate handling. AR400 is preferred when some formability or weldability is needed; AR500 is chosen for maximum abrasion resistance with minimal forming.
Core Technical Properties & Sizing
| Specification | AR400 | AR500 |
|---|---|---|
| Hardness (HBW) | 360 – 440 (typical 400) | 460 – 540 (typical 500) |
| Yield Strength (ksi) | 100 (690 MPa) | 120 (827 MPa) |
| Tensile Strength (ksi) | 125 (862 MPa) | 140 (965 MPa) |
| Elongation in 2" | 12% min | 10% min |
| Common Specifications | ||
| Standard Sizes (W x L) | 48" x 120", 48" x 240", 60" x 240", 72" x 240", 96" x 240", 96" x 480", 120" x 480" | |
| Thicknesses | 3/16", 1/4", 5/16", 3/8", 1/2", 5/8", 3/4", 1", 1-1/4", 1-1/2", 2" | |
| Flatness Tolerance | Per ASTM A6: 1/4" over 3' (≤ 1/2" thick); 3/8" over 3' (5/8" to 1"); 1/2" over 3' (> 1") | |
| Cutting Tolerance (Plasma) | ±1/16" (≤ 1/2"), ±1/8" (5/8" to 1"), ±3/16" (> 1") | |
| Weight | 40.8 lb/ft² per inch of thickness | |
Machinability, Tooling & Feeds
| Parameter | Recommendation |
|---|---|
| Machinability Rating | 40-50% of A36 mild steel |
| Tooling | Carbide inserts with AlTiN/TiAlN coatings (e.g., grade K313) |
| Drill Geometry | Carbide-tipped or solid carbide, 135° split point, peck drilling for depths > 3x diameter |
| Turning (SFM) | 200 – 300 SFM |
| Turning (Feed) | 0.008 – 0.015 IPR |
| Milling (SFM) | 150 – 250 SFM |
| Milling (Feed) | 0.004 – 0.008 IPT |
| Drilling (SFM) | 80 – 120 SFM |
| Drilling (Feed) | 0.002 – 0.005 IPR |
| Plasma Cutting | High-definition plasma: 40-60 A (1/2"), 80-130 A (1") |
| Oxyfuel Cutting | > 3/4" thick; produces harder HAZ (up to 600 HB) |
| Laser Cutting | Not recommended over 3/8" thick |
| Waterjet Cutting | Ideal for tight tolerances and minimal HAZ |
| Welding Electrodes | Low-hydrogen E7018 or E11018 |
| Preheat (AR400) | 200°F – 400°F |
| Preheat (AR500) | 300°F – 500°F |
| Interpass Temperature | Maintain below 500°F to avoid cracking |
| Post-Weld Cooling | Slow cool in lime or insulating blankets |
Common Defects & Quality Control
| Defect | Inspection Method | Acceptance Criteria |
|---|---|---|
| Surface Lamination / Scabs | Visual | Reject if deeper than 1/16" after grinding |
| Edge Cracks (Shearing/Burning) | Dye Penetrant | Reject if detected |
| Hardness Variation | Portable tester (Leeb / Brinell) — 3 locations per plate | ±20 HBW (AR400), ±30 HBW (AR500) |
| Warpage / Excessive Crown | Straightedge | Reject if exceeds ASTM A6 tolerance by more than 50% |
| HAZ Cracking (Near Cut Edges) | Visual / Grinding | Grind 1/16" off edge before welding |
| Mill Scale Inclusions | Visual | Remove by grinding or blasting before welding |
| Incorrect Thickness | Micrometer (4 corners + centre) | Per ASTM A6 tolerances |
| Sheared Edge Burr | Visual / Touch | Deburr to prevent injury and fit-up issues |
Storage, Handling & Racking Guidelines
| Aspect | Guideline |
|---|---|
| Storage Location | Indoors or under cover to prevent rust and moisture accumulation |
| Racking (≤ 1/2" thick) | A-frame or vertical racking to minimize warpage |
| Racking (> 1/2" thick) | Horizontal racking with wooden or rubber spacers every 4-5 feet |
| Floor Contact | Never stack directly on concrete; use 4x4 timbers or steel I-beams for air circulation |
| Handling Tools | Plate clamps with rubber pads for < 1/2"; C-hooks or lifting magnets for > 1/2" |
| Lifting Procedure | Always lift with two or more points to prevent bending |
| Cutting / Welding Support | Ensure plates are supported on a flat surface to avoid distortion |
| Long-term Storage | Apply light rust-preventive oil (e.g., LPS-3) and cover with a tarp |
| Inventory Management | Use FIFO system; label each plate with heat number, thickness, and date received |