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Hardfacing Cored Wires Welding lloy rou WA Cored Wires Hardfacing Cladding - Weld overlay - Surfacing 100% Welding Alloys technology and manufacturing This catalogue presents a selection of standard products for hardfacing, cladding and thermal Welding arc spraying applications. Welding Alloys cored lloy wires for joining applications feature in a separate rou catalogue. We will gladly examine any special request. Please do not hesitate to consult us. Our technical ‘spark’ solves your industrial challenges Since its foundation in 1966, the Welding Alloys Group, an independent group, has specialised Contents Introduction 2 in the manufacture of cored welding wires for joining, cladding and hardfacing applications – Definitions and using this catalogue 4 100% produced in our modern factories – 100% our own technology. Welding Alloys cored wires 5 Performance and quality criteria are becoming ever more stringent and require ever more Hardfacing 6 complex materials. Shortages of raw materials are leading increasingly to the development of Work-hardening manganese alloys 6 composite components, with surfacing provided by the hardfacing method, using sophisticated Low and medium alloys 8 alloys. Welding Alloys Group are proud to bring ground-breaking hardfacing technology to our Heat treated steels for tooling 10 customers. Anti-abrasion 12 Ferritic and mertensitic stainless steels 16 Welding Alloys performance guarantee means we will always recommend the product and Copper-aluminium alloy 18 service best suited to our customers’ applications. Nickel base 20 Cobalt base 22 Cladding 24 Packaging 27 Technical information 27 Alphabetical index 27 2 3 Definitions and using this catalogue Cored wires Subm er rc ge a d n a Hardfacing by arc welding is a surfacing operation to extend the service life of industrial components, preemptively on new e r p c components, or as part of a maintenance programme. The result of significant savings in machine downtime and production O costs has meant that this process has been adopted across many industries. Which G Which a g s n i s y Process Alloy h For each industrial application and wear phenomena, there is a Welding Alloys cored welding wire to provide wear resistance. a r i e p l d s Due to the unrivalled flexibility and ease of application, cored wires are used in many situations – in workshops, on site, for new e c d r a l a T parts or for repair. h m r e An alloy may be deposited by various welding methods: Sie and hape f r piece Srface finih reired ae maerial - chemical • Open arc welding (O) e hardfaced As welded, machined, polished cmpiin • Gas shielded welding MIG/MAG (G) perainal difficlie epi hicne - nmer f layer Wring cndiin Wring enirnmen • Submerged arc welding (S) Technical ecie Abrasion Welding in a workshop Performance Impact On site • Thermal spraying (as shown by the symbol) Reliability Thermal fatigue Aailale elding eipmen Service lifetime Corrosion Welding Alloys Quality Control teams are an integral part of the production process at all our production sites, to ensure our continued commitment to delivering high quality, standard-setting welding consumables. Understanding wear phenomena and material attributes Wear mechanism Description Metal surfaces in relative motion forced into contact with or without lubricant. Degradation by the formation of Metal / metal friction micro-welds between the contacting surfaces. Wear by relative movement of mineral particles of suitable hardness, shape and texture to remove material Mineral abrasion from the metal surface. Wear by relative movement under pressure of mineral particles of suitable hardness, shape and texture to Abrasion under pressure remove material from the metal surface, leaving superficial deformation. As above but in a high-temperature environment, leading generally to softening of the metal or its Hot abrasion constituents. Repeated high-speed impacts between mineral particles and a material surface. Local destruction by tearing Erosion out of metallic grains. Tearing out of grains from the metal surface by the formation and implosion of bubbles in a liquid in rapid Cavitation motion. Impact between two materials, one of which provokes deformation or rupture of the surface of the other. This Impact phenomenon is controlled by the toughness or ductility of the two materials. Cyclic deformation not exceeding the elastic limit of the material. Degradation over time by localised stress Mechanical fatigue concentrations. Cyclic exposure to high temperatures leading to permanent deformation by alternate expansion and Thermal fatigue contraction. Alteration of the structure and properties of the material. Hot oxidation Creation of a poorly adhering oxide layer that reforms constantly. Degradation by loss of material thickness. Degradation of the material by chemical reaction with its environment. Complex phenomenon involving Corrosion numerous parameters. Attributes Description Repair by resurfacing to the original or specified dimensions. Rebuilding or cladding Application of a corrosion-resistant protective cladding. Layer of weld metal providing a good metallurgical transition between the base metal and the coating. Buffer layer or assembly For welded joints between similar or dissimilar materials. Ability of the material to resist impact, heat, friction and abrasion simultaneously for edge retention of cutting Cutting ability tools. Ability of a material to increase its surface hardness under the effect of impact or high pressure. In general, Work-hardening this increases wear resistance. Machinability Suitability for machining by removal of metal shavings, e.g. turning, milling or drilling. The go-to provider Example: Chemical composition Composition [%] of advanced welding Each alloy is composed of elements expressed as percentages Product Name by weight. The values of those elements essential to the C Mn Si Cr physical, chemical and mechanical properties of the deposit consumables HARDFACE AP 0.40 0.50 are highlighted in the composition tables. 16.0 14.0 4 5 Hardfacing - Cladding - Thermal Arc Spraying Hardfacing - Work-hardening manganese alloys Shielding Gas and Flux Recommendations - HARDFACE (a cored wire with a seam) the recommended shielding gas is M21: Argon + 15-25% CO2 - ROBODUR / ROBOTOOL (a seamless cored wire) the recommended shielding gases are M12: Argon + 0.5-5% CO2 M13: Argon + 0.5-3% O2 M21: Argon + 15-25% CO2 - A neutral flux is required for submerged arc welding Composition [%] - Fe balance Hardness - 3 layers Product Name C Mn Si Cr Ni as welded work hardened HARDFACE 19 9 6 0.10 6.00 0.50 19.0 9.00 180 HB 47 HRC HARDFACE AP 0.40 16.0 0.50 14.0 240 HB 48 HRC HARDFACE NM14 1.00 14.0 0.50 200 HB 46 HRC Process Standard EN 14700 O: open arc diameters Product Name standard Description and applications G: gas-shielded [mm] S: sub-arc Metal / friction Mineral abrasion Abrasion under pressure Hot abrasion Erosion Cavitation Impact Mechanical fatigue Thermal fatigue Hot oxidation Corrosion Rebuilding or cladding layer or Buffer assembly Cutting ability Work-hardening Machinability O 1.2 to 2.8 • Highly resistant to cracking - austenitic structure that work-hardens strongly HARDFACE 19 9 6 G 1.2 to 2.4 T Fe10 u u u u u u u u u u • Wide field of application: buffer layer before hardfacing, assembly of wear plates and armouring, and of manganese steels and dissimilar joints S 2.4 to 3.2 O 1.2 to 2.8 • High rate of work-hardening G 1.2 to 2.4 • Non-magnetic deposit strongly resistant to impact and high pressure HARDFACE AP T Fe9 u u u u u u u u u • Rebuilding, buffer layers and assembly of manganese steels S 2.4 to 3.2 • Buffer layer before hardfacing with chromium cast iron • Applications: repair work on railway frogs and crossings, hammers, bars, cones and jaws for crushers O 1.2 to 2.8 Colour and structure of the deposit similar to Hadfield type manganese steel HARDFACE NM14 T Fe9 u u u u u u u u u u u u • G 1.2 to 2.4 • Applications: for retouching of casting imperfections Suited to thermal arc spraying u Suitable u u Highly suitable 6 7 Hardfacing - Cladding - Thermal Arc Spraying Hardfacing - Low and medium alloys Composition [%] - Fe balance Hardness Product Name 3 layers C Mn Si Cr Mo V as welded HARDFACE B 0.10 1.50 0.40 1.00 260 HB HARDFACE T 0.15 1.50 0.80 1.50 360 HB HARDFACE P 0.20 2.00 0.80 3.00 400 HB HARDFACE L 0.50 1.50 2.50 8.50 650 HB ROBODUR K 250 0.10 1.50 0.70 1.50 0.20 250 HB ROBODUR K 350 0.15 1.50 0.70 2.00 0.50 350 HB ROBODUR K 450 0.40 1.50 0.70 2.50 0.50 450 HB ROBODUR K 600 0.50 1.20 0.70 6.00 0.70 600 HB ROBODUR K 650 0.50 1.30 1.30 5.60 1.30 0.30 650 HB ROBODUR K CERAMIC 0.35 0.70 2.50 9.50 55 - 60 HRC HARDFACE – ROBODUR: for a description of shielding gas and flux recommendations – see page 6 Process Standard EN 14700 O: open arc diameters Product Name standard Description and applications G: gas-shielded [mm] S: sub-arc Metal / friction Mineral abrasion Abrasion under pressure Hot abrasion Erosion Cavitation Impact Mechanical fatigue Thermal fatigue Hot oxidation Corrosion Rebuilding or cladding layer or Buffer assembly Cutting ability Work-hardening Machinability O 1.2 to 2.8 HARDFACE B T Fe1 u u u u u u u u S 2.4 to 3.2 • Crack-resistant deposit O 1.2 to 3.2 • Repair, rebuilding and buffering of castings HARDFACE T T Fe1 u u u u u u u u S 2.4 to 3.2 • Automated welding of large parts, semi-automated welding for outdoor use O 1.2 to 2.8 • Applications: shafts, rollers, wheels, etc.
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