Hardfacing operations tend to standardize on one size wire for every application. This helps prevent confusion for the operator and minimizes inventory of welding tips, lines, and accessories. Smaller welding wires are attractive to operators because it is easier to control the weld deposit and they require less heat input. However, they can hinder deposition rate and travel speeds. When hardfacing thicker material the lower heat input can cause lack of fusion to the base metal.
Why switch to a larger diameter hardfacing wire? The need to increase production! The hardfacing operation is requiring higher deposition rates and faster travel speeds to meet production requirements. Large diameter wire is generally more alloy rich than smaller diameter wire.
Larger diameter wires are primarily metal-cored and flux-cored wires, (tubular metal sheath wrapped around a formula of metal powders). These wires require less heat input then solid core wires and provide a wider arc.
There are factors to keep in mind when switching to large diameter wire.
Each large diameter wire has recommended welding parameters which should be followed to maximize the hardfacing application.
POSTALLOY® Large Diameter Hardfacing Products
DuraHard™2825NC-MCG 5/64” Non-cracking martensitic alloy
DuraHard™2828NCTi-FCO 3/32”, 7/64” Flux-cored, Martensitic alloy with Titanium carbides
DuraHard™PS135-MCO 7/64”, 1/8” High hardness multi-carbide alloy
DuraHard™PS156N-FCO 7/64”, 1/8” Flux-cored, Non-cracking martensitic tool steel
DuraHard™PS158Ti-FCO 7/64”, 1/8” Flux-cored, Non-cracking alloy with Titanium carbides
DuraChrome™PS133-MCO 7/64”, 1/8” Chromium carbide overlay
DuraChrome™PS137-MCO 7/64”, 1/8” Chromium carbides in an austenitic mix
DuraChrome™2832-MCO 3/32”, 7/64” Premium chrome carbide
DuraChrome™2820-MCO 3/32”, 7/64” Chromium carbide for high impact combined with abrasion
DuraChrome™2818-MCO 7/64” Chromium carbide for high impact combined with abrasion
DuraMang™2865-FCO 7/64” Flux-cored, open arc austenitic chromium-manganese weld alloy
DuraBuild™2890-FCO 7/64” Flux-cored build-up wire applied to carbon and low alloy steel
Dredging Overlay Plate
Mines/Quarries Coal Pulverizer Rolls
Cement Crusher Rolls
Construction Crusher hammers, Asphalt mixer blades
Agriculture Tools, shears, plow blades
Oil and Gas Drill pipe