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Hardfacing and Wear Resistant Use Hardfacing and Wear Many Abrasions Occur Not Just Due to a Singular Cause, but Possibly Two Or More Welding Layers Limitation

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Hardfacing and Wear Resistant Use Hardfacing and Wear Many Abrasions Occur Not Just Due to a Singular Cause, but Possibly Two Or More Welding Layers Limitation 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 specifi c 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 fi ller metal to restore the base metal back to its original dimension on the working piece prior to hardfacing Resistant Use Hardfacing and Wear welding. 2. Buttering When the fi ller 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 fi ller 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 fi ller metal : Hardfacing General Review Welding fi ller metal is selected according to the following criteria : 1.Base metal will affect the selection of fi ller 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 fi ller 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, fi lter, 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, fl y wheel, razor, scissors, or bearing surface. D2 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 Alloy Type Microstruc- Properties Application or industrial equipment’s shovel teeth, cutter, etc. 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 13%Mn Steel, crusher casting guide roller, etc. 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 Hardfacing and Wear Resistant Use Hardfacing and Wear many abrasions occur not just due to a singular cause, but possibly two or more welding layers limitation. Resistant Use Hardfacing and Wear simultaneously; thus, the selection of hard facing fi ller metal must use abrasion type as the main consideration in determining selection priority. Use as surface layer; serve as buttering of buffer layer; gear, shovel roller, sometime it is used as fi nal 3.welding process buffer layer bainite chain roller, clutch rod, low alloy hardfacing layer especially and welding + guide roller and The main determinant of selecting welding process is based on the restoring content in good crack resistance joint repair pearlite buttering for buffer equipment’s measurement and quantity; welding position; available welding equipments; weld metal or when good layer. and the necessary frequency of hardfacing; with its common welding processes as the 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 fl y wheel, and welding position. metal medium and small to large metal friction or sliding (no conveyor connecting 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 Material General Review abrasion) wear resistance. conveyor. deposition effi ciency than SMAW. Welding consumables selection Welding (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 abrasion carbonate sion. Contains suffi cient hammer, sand agitator due to its high deposition effi ciency, the productivity is greatly enhanced which can be contents (impact and content carbonate, able to resist blade, sieve, cement acquired through the methods below : (containing wearing) alloyed type wearing at very low stress agitator , dredge cut- (A) Neutral fl ux pairs up with alloyed wire (also commonly known as composite wire). carbonate) (B) Alloyed fl ux matches up with carbon steel wire. condition. ter, agriculture shovel. (C) Using partial self-shield fl ux cored wire, fl ux may be used or not depending on the Good resistance for metal sand blast nozzle, need. to sand stone or rock crush- coal crusher, crushing ing or grinding; or use in large quantity roller, auger, conveyor 4. The polarity illustration : 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 fi n 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) D3 D4 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 MXW MANG 1 otherwise blow holes will most likely to occur. In addition, when the base metal has cracked ~ 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 Hardfacing and Wear Resistant Use Hardfacing and Wear Resistant Use Hardfacing and Wear 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 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 35 MXW K107-S taken into consideration. GH450R BU-G ~ MXW K105-S GH600 MXW BB-G 54 MXW K102-S Table 1 : base metal carbon equivalent and preheat & inter pass temperature reference value GH600R MXW 102-G Crane wheel Excavator pre-heat and inter pass Steel Type Carbon Equivalent temperature MXW D Notes Welding GH750 ≦0.3 ≦100°C MXW DD-G GH900 >0.3 but ≦0.4 ≧100°C MXW 969-G 40 GH900W >0.4 but ≦0.5 ≧150°C MXW 969-O MXW R100 Welding consumables selection Welding ≦ ≧ ~ HARD D Carbon Steel >0.5 but 0.6 200°C MXW M7-G MXW R101 64 HARD 31 Shovel Scraper >0.6 but ≦0.7 ≧250°C MXW R117 HARD 35 teeth cutter >0.7 but ≦0.8 ≧300°C MXW R100 GH800 >0.8 ≧350°C 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 GHCW MXW 66-O MXW 66-O 2. Post weld heat treatment is needed according to base metal alloy contents or carbon 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 b. Post heating after welding ~ GH13Cr-4 GMX 410NiMo MXW K420-S 55 MXW K423-S Recommending 300~350°C post heating immediately after welding and sustain 10-30 Valve disk minutes to avoid cracking.
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