Hardfacing and Wear Resistant Use

Hardfacing General Review

Hardfacing process is the most economical way to allow a work to achieve maximum
application and usage longevity. As it name suggests, hardfacing is to build up upon the
softer base metals’ surface one or multi-layers of hardfacing alloys according to specific
needs.

There are commonly three types of welding process to restore abrasive of wear out work :

1. Build-up
If the project base metal suffers great abrasion, use the proper filler metal to restore
the base metal back to its original dimension on the working piece prior to hardfacing
welding.

Hardfacing General Review

2. Buttering
When the filler metal for hardfacing layer and the base metal’s mechanical properties
along with physical property have great variation, it is difficult to weld the two together;
hence, it is essential to select the proper filler metal for the project base metal to serve as a
buffer in reducing the incompatibility.

3. Hardfacing
Hardfacing and Wear Hardfacing also known as surface hardening welding is achieved by welding the wear
resistant layer onto base metal or surface layer for the purpose of extending the longevity
Resistant Use of mechanical equipment. It is normally limited to two to three welding layers.

How to select the proper hardfacing filler metal :

Welding filler metal is selected according to the following criteria :
1.Base metal will affect the selection of filler metal for base (root ) layer, for example:
a. Mn Steel: for equipment suffered severe impact condition. Use high Mn content filler
metal to restore the base metal to its original size.
b. Carbon steel or low alloy steel: directly use low alloy hardfacing filler metal to restore its
size.

2. Abrasion types as following :

a. severe abrasion:
Severe abrasion is often accompanied by high stress concentration and low impact
level. The work could possibly involve rolling over rigid minerals or serving as surface
blocking corrosive material. The usages typically are agricultural machinery equipment,
metallic sieve, filter, pulpous material conveyor pump.
b. severe impact:
Severe striking or pounding could cause the metal surface to crack, crush, or cratering.
The usages typically are repair welding on coned mining crusher, hammering crusher,
impactor bars, rail frogs and crossings.
c. metal to metal (friction or stick to) :
Metal to metal spinning or sliding against each other. Usages such as roller, fly wheel,
razor, scissors, or bearing surface.

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Hardfacing and Wear Resistant Use

Hardfacing and Wear Resistant Use

Welding consumables selection
d. metal to sand (impact and abrasion) :
The main cause of wearing is sand which has mild impact character. The wear comes
from simultaneous movement of impact and wearing. Usages are excavator, agriculture Weld Metal
Abrasion
or industrial equipment’s shovel teeth, cutter, etc. Alloy Type Microstruc- Properties Application
Type
e. wearing at elevated temperature: ture
This type of wear is accompanied by high temperature during working. Examples are hot High impact toughness and
forging die, steel milling shop, hot press roller, heat exchanger blade, die tool, continuous superior work hardening
casting guide roller, etc. 13%Mn Steel, crusher
severe im- High Mn austenite ability. As welded condition
hammer, impacter,
f. wearing under corrosion environment (ablation) : pact Steel structure application with no need to
rail coupling.
Chemical corrosion in usages such as chemistry lab apparatus and equipment. Actually measure hardness, and no
many abrasions occur not just due to a singular cause, but possibly two or more welding layers limitation.
simultaneously; thus, the selection of hard facing filler metal must use abrasion type as
the main consideration in determining selection priority. Use as surface layer; serve

Welding consumables selection

as buttering of buffer layer;
gear, shovel roller,
Material General Review

sometime it is used as final

3.welding process buffer layer bainite chain roller, clutch rod,
low alloy hardfacing layer especially
The main determinant of selecting welding process is based on the restoring and welding + guide roller and
content in good crack resistance
equipment’s measurement and quantity; welding position; available welding equipments; joint repair pearlite buttering for buffer
weld metal or when good
and the necessary frequency of hardfacing; with its common welding processes as the layer.
machining ability is called
following : for.
(1) SMAW (Shielded Metal Arc Welding) :
Using stick electrode requires minimum tools, least consideration of welding location metal to To be used for metal to bulldozer fly wheel,
metal medium and small to large metal friction or sliding (no conveyor connecting
and welding position.
abrasion low alloy quantity of lubrication). Holds medium parts, shovel cutter
(2) Semi Auto Welding :
(sticky content martensite to high hardness and high edge, screw type
Using wire feeder, self shield or gas shield flux cored wire has comparable higher abrasion) wear resistance. conveyor.
deposition efficiency than SMAW.
(3) Automatic Welding : Good resistance for metal bulldozer cutter edge,
medium
This requires more complicated welding equipment and pre-welding preparation, but metal to sand medium to sand impact and abra- shovel teeth, impact
alloy
due to its high deposition efficiency, the productivity is greatly enhanced which can be abrasion carbonate sion. Contains sufficient hammer, sand agitator
contents
acquired through the methods below : (impact and content carbonate, able to resist blade, sieve, cement
(containing
(A) Neutral flux pairs up with alloyed wire (also commonly known as composite wire). wearing) alloyed type wearing at very low stress agitator , dredge cut-
carbonate)
condition. ter, agriculture shovel.
(B) Alloyed flux matches up with carbon steel wire.
(C) Using partial self-shield flux cored wire, flux may be used or not depending on the Good resistance for metal
need. sand blast nozzle,
to sand stone or rock crush-
coal crusher, crushing
ing or grinding; or use in
4. The polarity illustration : large quantity roller, auger, conveyor
severe severe metal surface wear
carbonate carbonate screw rod, crusher
DCEP ( DC+ ): Electrode positive or DC reverse polarity. abrasion condition. Normally used
alloy parts, agricultural
DCEN ( DC– ): Electrode negative or DC straight polarity. in environment with high
tools, shovel teeth,
press stress and medium to
hot ash elbow.
low impact characteristics.

metal to
heat exchanger fin
metal of heat
blade, die tool, turbine
fatigue resis-
13% Cr Holds superior corrosion blade, heat resistant
tant abra- 13% Cr
series stain- resistance and heat fatigue valve gate, chemical
sion ( high martensite
less steel resistance characteristics. containers, equipment
temperature
and continuous
or corrosion
casting rollers.
condition)

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Hardfacing and Wear Resistant Use

Hardfacing and Wear Resistant Use

Welding Notes

Products To obtain the ideal hardfacing result and minimize cracking, carefully select the proper
alloyed hardfacing filler metal and welding procedure is recommended; Pay attention to the
Hardness SMAW SAW (Submerged Abrasion category following additional points :
Flux Cored wire
HRC Electrode arc welding wire) 1. base metal preparation
Surface corrosive and impure material such as grease, dirt, etc. must be removed;
15 GH13M otherwise blow holes will most likely to occur. In addition, when the base metal has cracked
MXW MANG 1
HARDMANG 1 —
~

MXW MANG 3 already, the weld metal will continue to suffer cracks as well; thus, the defects on the base
50 HARDMANG 3 Rail coupler metal must be removed before welding.
2. Heat input and temperature control
15 GH300 In order to lessen cracking occurring, consult the following guidance :
MXW BU-O a. Pre-heat and inter pass temperature control
GH300R MXW K104-S
~

MXW BU-G
Welding consumables selection

39 GH350R Buffer layers before This is one effective step to avoid cracking. The chart lists base metal’s carbon
hardfacing equivalent (Ceq) and the recommended preheat and inter pass temperature. During
actual welding, the work’s size, thickness, filler metal and welding process should be
GH450 MXW SUPER taken into consideration.

Welding Notes
35 MXW K107-S
GH450R BU-G
MXW K105-S
~

GH600 MXW BB-G Table 1 : base metal carbon equivalent and preheat & inter pass temperature reference value
54 MXW K102-S
GH600R MXW 102-G Crane wheel　Excavator
pre-heat and inter pass
Steel Type Carbon Equivalent
temperature
MXW D ≦0.3 ≦100°C
GH750
MXW DD-G >0.3 but ≦0.4 ≧100°C
GH900
MXW 969-G >0.4 but ≦0.5 ≧150°C
40 GH900W
MXW 969-O MXW R100 Carbon Steel >0.5 but ≦0.6 ≧200°C
HARD D
~

MXW M7-G MXW R101 >0.6 but ≦0.7 ≧250°C

64 HARD 31 Shovel Scraper
MXW R117 teeth cutter >0.7 but ≦0.8 ≧300°C
HARD 35
MXW R100 >0.8 ≧350°C
GH800
MXW R101
No need to pre-heat, but inter pass temperature must be
Mn Steel (13%Mn)
controlled below 260°C.
MXW R100 MXW R100 No need to pre-heat, inter pass temperature is below
Austenite Stainless Steel
HARD 35 MXW R101 MXW R101 150°C.
GH800 MXW R100D MXW R100D
High Alloy Steel
55 GH900Mn MXW R100SHD MXW R100SHD Above 400°C.
(high Chromium Carbide)
GH950Nb MXW 62-O MXW 62-O
~

68 GH950 MXW 63-O MXW 63-O Remark :

GH950C MXW 65-O MXW 65-O Crusher Coal 1. Ceq % = C + Mn / 6 + Si / 2 4 + Cr / 5 + Mo / 4 + Ni / 15.
wheel crusher 2. Post weld heat treatment is needed according to base metal alloy contents or carbon
GHCW MXW 66-O MXW 66-O
wheel
MXW 70-O MXW 70-O equivalent.
3. The 300 series’ austenite stainless steel not included in the high alloy steel section.

35 MXW K410NiMo-S
GH13Cr-4 GMX 410NiMo MXW K420-S b. Post heating after welding
~

55 MXW K423-S Recommending 300~350°C post heating immediately after welding and sustain 10-30
Valve disk minutes to avoid cracking. Do not over heating or might cause hardness decline.

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Hardfacing and Wear Resistant Use

c. Post Weld Heat Treatment

Post weld heat treatment of 550~750°C can effectively avoid cracking, less
deformation and improve weld metal characteristics. Make sure hardness criteria is
reasonable prior to post weld heat treatment.

3. Buffer layer
When base metal requires a layer of extreme hard high alloy content weld metal,
make sure to weld on a layer of lower alloy content buffer layer to avoid cracking.

4. Penetration
During hardfacing welding operation, the weld metal’s characteristics will be changed
according to the degree of penetration from filler and base metal’s mutual dilution. Usually
the filler metal’s chemical composition differs from the base metal; to achieve ideal
hardness and characteristics for the weld metal, use as often as possible multi-passes
technique in order to avoid high penetration and high dilution.
Welding Notes

5. Welding deformation
To decrease work piece’s deformation, use short bead, intermittent technique,
symmetric welding technique, or fasten the work piece into stationary position before
welding.

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