Viability of button melting for accelerated development of chromium carbide overlay

Abstract

To accelerate overlay design and development, button melting method is compared with wire fabrication and welding. For the same overlay alloy, similar microstructure and hardness are produced by both methods. It is viable to use button melting in replace of wire fabrication. However, there is no dilution from base metal in button melting, and the microstructure consists of more directionally solidified grains due to the predominant directional cooling. Button melting also produces faster cooling rates that enhance formation of martensite in the steel matrix.