Hardfacing Deposits Research Articles

Effect of dilution on GTAW Colmonoy 6 (AWS NiCr–C) hardface deposit made on 316LN stainless steel

Nickel based Colmonoy 6 (conforming to AWS NiCr–C) hardfacing alloy finds application in hardfacing of various components made of austenitic stainless steel (SS) used in fast reactors. Owing to considerable difference in melting points of the SS and Colmonoy 6 alloys, significant dilution from substrate occurs during hardfacing using gas tungsten arc welding process. Dilution has a significant effect on microstructure, hardness and wear resistance of the deposit. To overcome the adverse effects of dilution on the hardness and, hence, the wear resistance of the deposit, often, the minimum thickness specified for the deposit on hardfaced components is high, which in turn increases the susceptibility of the deposit to cracking during deposition. In the present investigation, microstructure of different layers of multilayer Colmonoy 6 deposits on 316LN SS is characterised by optical and scanning electron microscopy, and the correlation between hardness and microstructure of the individual layers with dilution from the base metal has been established. The dilution from the base material is the highest in the first layer, and it progressively decreases in the subsequent layers. With progressive decrease in dilution, the precipitate fraction increases from about 16 to 20% from the first to the fifth deposit layers. This is accompanied by hardness increase from about 480 to 800 HV. The precipitates in the deposit consist of both borides and carbides, with the boride content varying more with dilution than the carbide content. The boride fraction increased from 5 to 8% with a decrease in dilution; however, layer to layer variation in carbide fraction was only marginal at about 11–12%. High dilution from the base material suppresses the formation of borides in the deposit and is responsible for low hardness of the deposit diluted with the austenitic SS compared to those of the undiluted deposit.

Hardfacing of austenitic stainless steel with nickel-base NiCr alloy

Fast breeder reactors components encounter adhesive/abrasive wear nature and erosion. Hardfacing by weld deposition improves resistance to high temperature wear, especially galling, of mating surfaces in sodium. Based on induced radioactivity rate and shielding considerations, nickel-base E NiCr-B hardfacing alloy was chosen to replace cobalt-base Stellite alloys. Studies on this hardface deposit on austenitic stainless steel substrate demonstrated that deposits after exposure at service temperatures up to 823 K would retain adequate hardness (> RC 40) at end design service-life of 40 years. Also, the plasma transferred arc welding process was chosen for hardfacing to ensure that width of dilution zone could be controlled by optimising deposition parameters. The selection of nickel-base hardfacing alloy and deposition process used for development of hardfacing technology for various components of the Indian prototype fast breeder reactor is discussed.

Effect of welding procedure on wear behaviour of a modified martensitic tool steel hardfacing deposit

In the last years hardfacing became an issue of intense development related to wear resistant applications. Welding deposits can functionalize surfaces and reclaim components extending their service life. Tool steels are widely used in hardfacing deposits to provide improved wear properties. Nevertheless systematic studies of wear behaviour of new alloys deposited by hardfacing, under different service conditions are scarce. In this work the effects of shielding gas, heat input and post-weld heat treatment on the microstructural evolution and wear resistance of a modified AISI H13 martensitic tool steel deposited by semi-automatic gas shielded arc welding process using a tubular metal-cored wire, were studied. Four coupons were welded with different welding parameters. The shielding gases used were Ar–2% CO 2 and Ar–20% CO 2 mixtures and two levels of heat input were selected: 2 and 3 kJ/mm. The as welded and 550 °C–2 h post-weld heat treated conditions were considered. From these coupons, samples were extracted for testing metal–metal wear under condition of pure sliding with a load of 500 N. Chemical compositions were determined; microstructure and microhardness were assessed. It was found that content of retained austenite in the microstructure varied with the welding condition and that heat-treated samples showed secondary hardening, associated with precipitation phenomena. Nevertheless, as welded samples showed higher wear resistance than heat treated specimens. Under these test conditions post-weld heat treatment led to a reduction in wear resistance. The best wear behaviour was observed in samples welded with low heat input and under the lowest oxygen potential shielding gas used here, in the as welded condition. The intervening mechanism was mild oxidative. These results were explained in terms of the relative oxidation resistance stemming from different welding conditions.

Study of Magnetism in Colmonoy-6 (AWS NiCr-C) Deposit on 316LN Stainless Steel

Considerable difference in melting points between the austenitic stainless steel (SS) substrate and Ni-base Colmonoy (AWS NiCr) hardfacing alloys results in significant dilution of the hardface deposit from the substrate. In the present study, it is found that the dilution also affects the magnetic property of the deposit. Although both austenitic SS and the undiluted Ni-base hardfacing alloy deposit are non-magnetic, the deposit diluted by austenitic SS becomes magnetic. Magnetism at different dilution levels of the deposit is measured using Magnegage and Feritscope, and the results correlated with the dilution of the deposit that is estimated from its Fe and Ni contents using SEM-EDS analysis. A good correlation between dilution and magnetic property could be obtained. As dilution also affects the hardness of the deposit, it was also possible to correlate the magnetic property of the deposit with its hardness. These findings have potential application in using magnetic measurement as a non-destructive method for estimating the hardness and/or dilution of the deposit on actual components not amenable for in-situ hardness measurements. The possible origin of magnetism in the deposit layers has been examined. The small variations in the lattice parameters of the deposit with dilution (composition) could be well correlated with variation in magnetic property.

The effects of welding processes on abrasive wear resistance for hardfacing deposits

In this research, four kinds of welding deposits were evaluated, applied through two different welding processes: flux cored arc welding (FCAW) and shielded metal arc welding (SMAW). The other variable of the tests was the deposited layers. The hardfacing deposits were evaluated using the dry sand-rubber wheel machine according to procedure A of the ASTM G65 standard. Optical and scanning electron microscopy was used for the characterization of the microstructure and worn surface of deposits. FCAW welds presented higher abrasive wear resistance than the SMAW deposits. The hardfacing deposit formed by uniformly distributed carbides rich in titanium presented the highest abrasive wear resistance. Abrasive wear resistance was higher when three layers were applied, except for SMAW-D deposit. It was not possible to get a clear relation between hardness and the abrasive wear resistance of the deposits. The results showed that the most important variable to improve abrasion resistance is the microstructure of hardfacing deposits, where the carbides act as barriers to abrasive particle cutting.

Friction-induced work hardening of cobalt-base hardfacing deposits for hot forging tools

Cobalt-base materials are widely used as weld hardfacing deposits in hot forging industry. When the cobalt-base hardfacing alloys are deposited using the MIG welding process, the weld energy with the sequences of the welding are at least the two important variables which influence the behaviour of most hardfacing deposits in service conditions. The purpose of this work is to consider their role in connection with the work-hardening ability of Stellite 21 weld hardfacing deposits. An experimental parametric study of several welded-layers related to their friction behaviour is performed. The friction-induced work hardening (FIWH) ability of Stellite 21 deposits is considered to assess the influence of the two welding parameters. Results show that depending on the used welding sequences, the amount of the applied energy determines the dilution rates across the thickness of the deposits. Microscopic observations at the friction surface confirm that the highest FIWH rates, owing to stacking faults brought out, increase the wear resistance.

Effects of dilution on microstructure and wear behaviour of NiCr hardface deposits

The effect of dilution on the microstructure, hardness and wear properties of two nickel base NiCr hardfacing alloys deposited using the gas tungsten arc welding (GTAW) process has been studied. Dilution from the base metal altered the microstructure, volume fraction and type of precipitates in the deposit, all of which varied with the distance from the deposit/substrate interface. The microstructural variation in the deposit was accompanied by corresponding variation in the deposit hardness. A pin on disc wear test, carried out using pins with varying thickness of deposit, showed that the wear resistance of the deposit increased with increasing thickness of the deposit, indicating that the wear resistance decreases with increasing dilution from the base metal. The present study brings out the effect of dilution from the substrate material on the properties of NiCr hardface deposits and the need to ensure a minimum thickness of GTAW deposits of these hardfacing alloys for obtaining the desired wear resistance.

Microstructural aspects of plasma transferred arc surfaced Ni-based hardfacing alloy

In the current investigation, nickel-base hardfacing alloy AWS NiCr-B was deposited on austenitic stainless steel substrate 316 LN using the plasma transferred arc-welding process. The deposit was characterized by hardness measurements, microstructural examination and sliding wear assessment. Identification of precipitates was carried out using X-ray diffraction, scanning electron microscope/energy dispersive X-ray analysis (SEM/EDAX), electron probe micro analyzer (EPMA) mappings and line-scan profiles. The microstructure of the hardfacing deposit predominantly consists of the γ-Ni phase and the interdendritic eutectic mixture comprised of γ-nickel and nickel-rich borides. These studies also revealed the presence of chromium-rich carbides and borides in a γ-nickel matrix. The sliding wear behaviour of the hardfacing alloy was investigated in air at three different temperatures viz., room temperature, 300 and 500 °C. The study revealed significant weight loss at room temperature and abrupt decrease at high temperatures. This behaviour at high temperatures has been attributed to the formation of a wear protective oxide layer at the surface during sliding. To evaluate the microstructural stability of the deposit, ageing studies were carried out at 650 °C for 250 h. Microstructural examination and hardness testing revealed that there is no deterioration in the microstructure and that the hardness remains intact. Sliding wear tests at room temperature and at high temperatures also demonstrated that there is no significant change in the weight loss or the wear behaviour after the thermal exposure.

Characterisation of nickel based hardfacing deposits on austenitic stainless steel

Nickel based hardfacing alloys Colmonoy-5 and Colmonoy-6 deposited on type 316L austenitic stainless steel substrate using the gas tungsten arc welding process, were characterised for their microstructure and hardness variations across the deposit/substrate interface, and for identification of the principal precipitates present in these hardface deposits. Hardness measurements and electron probe microanalysis (EPMA) across the interface revealed the presence of a dilution zone 2·5 mm wide in the Colmonoy-6 deposit and 1·5 mm wide in the Colmonoy-5 deposit. EPMA and X-ray diffraction studies of the precipitates showed that he blocky type precipitates were chromium borides and the needle-like precipitates were chromium carbides. Also, stress relief heat treatment at 1123 K for 4 h was found to have no significant effect on the hardness of these hard face deposits.

Selection of hardfacing material for components of the Indian Prototype Fast Breeder Reactor

Nickel-base hardfacing alloys have been chosen to replace cobalt-base alloys as hardfacing material for components of the Indian Prototype Fast Breeder Reactor, for minimising the dose rate to personnel during maintenance and decommissioning, and to reduce the shielding thickness required for component handling. Induced activity, dose rate and shielding computations showed that replacing cobalt-base alloys with nickel-base alloys for hardfacing of components would result in a marked reduction in both the dose rate from the components and the thickness of lead handling flasks. Long-term ageing studies on the nickel-base hardface deposits on austenitic stainless steel showed that the hardface deposit would retain adequate hardness at the end of the components' design service-life of 40 years of exposure at 823 K.

Development of hardfacing material in Fe-Cr-Nb-C system for use under highly abrasive conditions

The present paper summarises theoretical and experimental work undertaken to develop a hardfacing product designated '167Nb-S'. This material, which is based on the Fe-Cr-Nb-C system, was designed for cladding components subjected to severe abrasive wear by submerged arc welding. The work undertaken includes microstructural characterisation, solidification modelling and abrasion testing. The microstructure of 167Nb-S consists of a large volume fraction of primary niobium carbides, surrounded by a martensitic matrix containing fine quasi-eutectic niobium carbides. Some retained austenite is found along grain boundaries, together with small amounts of intermetallic phase. Alloy development enabled a reduction in the amount of retained austenite and intermetallic phase present in early versions of the alloy, which is beneficial in terms of abrasive wear resistance and weld cracking susceptibility. Standard three body abrasion tests showed that 167Nb-S exhibits wear rates comparable to those of high carbon/high chromium hardfacing deposits with similar hardness. The material 167Nb-S offers many advantages over conventional hardfacing products as high quality multilayer deposits with hardness up to 61 HRC can be deposited crack free, and these remain machinable. A highly successful application of this material is the cladding of roller press rollers, as an alternative to titanium containing hardfacing consumables or segments.

Laser Cladding of Austenitic Stainless Steel with Hardfacing Alloy Nickel Base

A nickel base alloy Colmonoy 6 was chosen as a candidate material for hard facing many components in the prototype fast breeder reactor. This alloy offers outstanding wear resistance and high hardness at elevated temperatures. Previous research using the gas tungsten arc welding process revealed that the hardness of the deposit is influenced by the dilution from the base metal up to a deposit thickness as high as 2.5 mm. The present study aims to control the level of dilution in the hard face deposits by carrying out deposition using a low heat input laser cladding process. The samples were characterised by macroscopic and metallographic examination, and microhardness measurements, SEM - EDAX and XRD analysis were used to determine their properties. The study demonstrated that by controlling laser cladding parameters, thin deposits with a low level of dilution can be laid on austenitic stainless steel substrate. Cracking of the deposit was minimised by controlling the heating and cooling rates.

A novel procedure for fabrication of wear-resistant bushes for high-temperature application

Wear-resistant bushes, for high-temperature application, made of hardfacing alloys are required in various components for in-sodium service in the prototype fast breeder reactor (PFBR). For this purpose, bushes of Colmonoy 6, a nickel-base high-temperature wear-resistant hardfacing alloy, have been fabricated using a novel procedure involving weld deposition of the hardfacing alloy on austenitic stainless steel (SS) rods by the gas tungsten arc welding (GTAW) process followed by precision machining of the hardface deposits. Ultrasonic examination of the hardface deposits and the machined bushes, as also achieving the dimensional tolerance and surface finish on the bushes as per specification, confirmed the success of this fabrication procedure. Microstructural examination showed uniform distribution of precipitates throughout the thickness of the bush. The hardness obtained across the thickness and along the surface of the bush was well above the specified limit of 540 VHN (52 R C). Dimensional measurements after fabrication and thermal ageing at the service temperature of 823 K for 24 h and 1000 h confirmed dimensional stability of the bushes fabricated using the above procedure.

Some observations of the influence of δ-ferrite content on the hardness, galling resistance, and fracture toughness of selected commercially available iron-based hardfacing alloys

Iron-based weld hardfacing deposits are used to provide a wear-resistant surface for a structural base material. Iron-based hardfacing alloys that are resistant to corrosion in oxygenated aqueous environments contain high levels of chromium and carbon, which results in a dendritic microstructure with a high volume fraction of interdendrite carbides which provide the needed wear resistance. The ferrite content of the dendrites depends on the nickel content and base composition of the iron-based hardfacing alloy. The amount of ferrite in the dendrites is shown to have a significant influence on the hardness and galling wear resistance, as determined using ASTM G98 methods. Fracture-toughness (K IC) testing in accordance with ASTM E399 methods was used to quantify the damage tolerance of various iron-based hardfacing alloys. Fractographic and microstructure examinations were used to determine the influence of microstructure on the wear resistance and fracture toughness of the iron-based hardfacing alloys. A crack-bridging toughening model was shown to describe the influence of ferrite content on the fracture toughness. A higher ferrite content in the dendrites of an iron-based hardfacing alloy reduces the tendency for plastic stretching and necking of the dendrites, which results in improved wear resistance, high hardness, and lower fracture-toughness values. A NOREM 02 hardfacing alloy has the most-optimum ferrite content, which results in the most-desired balance of galling resistance and high K IC values.

The fracture toughness and toughening mechanisms of nickel-base wear materials

Nickel-base wear materials are typically used as weld hardfacing deposits, or as cast or hot isostatically pressed (HIP) inserts that provide the needed wear resistance to a base material with the desired mechanical properties. Most nickel-base wear materials contain high levels of chromium, silicon, carbon, and boron, which results in complex microstructures that are comprised of high volume fractions of silicide, carbide, and/or boride phases. The volume fraction of nickel-phase dendrite regions typically ranges from 40 to 70 pct, and these dendrite-phase particles are individually isolated by a matrix of silicide, carbide, and boride phases. The continuous matrix of brittle silicide, carbide, and boride phases results in a low damage tolerance for nickel-base wear materials, which is a concern in applications that involve high stresses, thermal transients, or shock loading. Fatigue crack growth (FCG) and fracture toughness (K IC) testing in accordance with ASTM E399 methods has been used to quantify the damage tolerance of various nickel-base wear materials. Fractographic and microstructure examinations were used to define a generic toughening mechanism for nickel-base wear materials. The toughness of nickel-base wear materials is primarily controlled by the plastic deformation of the nickel-phase dendrites in the wake of a crack moving through the matrix of brittle silicide, carbide, and/or boride phases, i.e., crack bridging. Measured K IC values are compared with calculated K IC values based on the crack-bridging model. Microstructure examinations are used to define and confirm the important aspects of the crack-bridging model. This model can be used to predict the toughness values of nickel-base wear materials and direct processing methods to improve the K IC values.

Laboratory galling tests of several commercial cobalt-free weld hardfacing alloys

Since the mechanical properties of most wear materials are generally insufficient for structural applications, hardfacing alloys have been traditionally weld deposited to provide a wear resistant surface for a base material. An important attribute of a hardfacing alloy that is subjected to high load sliding contact is the resistance to adhesive (galling) damage. Although Co-base hardfacing alloys generally possess excellent galling wear resistance, there is interest in developing cobalt-free replacement hardfacings to reduce radiation exposure costs. A laboratory galling test has been developed for weld hardfacing deposits that is a modification of the standardized ASTM G98-91 galling test procedure. The procedure for testing a weld hardfacing deposit on a softer base metal using a button-on-block configuration is described. The contact stresses for the initiation of adhesive galling damage were measured to rank the galling resistance of several commercial Fe-base, Ni-base and Co-base hardfacing alloys. Although the galling resistance of the Fe-base alloys was generally superior to the Ni-base alloys, neither system approached the excellent galling resistance of the Co-base alloys. Microstructure examinations were used to understand the micromechanisms for the initiation and propagation of galling damage. A physical model for the initiation and propagation of adhesive wear is used to explain the lower galling resistance for the Ni-base hardfacings and to understand the influence of composition on the galling resistance of Ni-base alloys. The composition of some Ni base hardfacings was modified in a controlled manner to quantify the influence of specific elements on the galling resistance.

Study on Wear Behaviour of Fe-Cr-C Hardfacing Deposits

Study on Wear Behaviour of Fe-Cr-C Hardfacing Deposits

Alloy classification of hardfacing materials

The detailed nature of abrasive and impactive wear are discussed briefly, after which the various processes used for the laying down of hardfacing materials on metallic surfaces are described. The advantages and disadvantages of the various processes are considered in detail. The primary section of this paper consists of a classification of the consumables utilized in the hardfacing processes. Inherent in this classification the hardness level of the hardfacing deposit is considered as a function of the total alloy content. Also this classification demonstrates that the consumables can conveniently be separated into eight groups, five of which relate to the so-called alloy type and three to the hardfacing type, which consists of particles of the primary carbide phase dispersed in an iron-rich matrix. A brief metallurgical description is offered for each individual group, together with typical areas of application.

4842937 Method of depositing a wear-protective layer on a cutting tool and wear protective layer produced by the method : Hans-Robert Meyer, Hans-Joachim Wiemann, Hamburg, Federal Republic Of Germany assigned to Ernst Winter & Sohn (GmbH & CO)

In hot working processes the wear due to abrasion and adhesion has proved to be an important limiting factor in the service life of tools. In the present paper the wear resistance of different hardfacing deposits is studied. The laboratory wear tests were carried out using a wear testing machine allowing tests in hot working conditions. The results of the laboratory tests were then compared with the experience gained from industrial processes. On the basis of the results, the effects of different surfacing materials on the service life of hot-forming tools are discussed.

Comparison of the microstructures and abrasive wear properties of stellite hardfacing alloys deposited by arc welding and laser cladding

The microstructure of cobalt-based hardfacing alloys deposited by manual metal arc (MMA) welding, tungsten inert gas (TIG) welding, and laser cladding has been investigated as part of a study attempting to establish the relationship between microstructure and abrasive wear properties. For typical deposition conditions, the differences in freezing rates associated with the three processes are found to give rise to large differences in microstructure. The MMA process is found to lead to the largest degree of dilution of the hardfacing deposit; the TIG and laser deposits exhibited much lower levels of mixing with the base plate. For the deposition conditions used in this study and for the alloys examined, the scale of the microstructure decreases in the order MMA, TIG, and laser cladding, leading to an increase in the deposit hardness in the same order. It is found that with alumina as an abrasive, the wear rate persistently is higher with the MMA deposits (which have the coarsest microstructure with the lowest starting hardness), the weight loss being approximately linear with time. The laser and TIG deposits, which have more refined microstructures and slightly higher carbon concentrations, both are found to exhibit significantly lower wear rates. Initially, the TIG samples are the most resistant to abrasion, even though their microstructure compares with that of the laser samples; this is a consequence of their higher ductility associated with a lower rate of strain hardening. The laser samples, which contain a lower matrix iron concentration, strain harden more rapidly; consequently, they exhibit an initial decrease in wear rate. With the much harder silicon carbide abrasive, all samples show similar wear rates which do not decrease with time. The wear data are found to correlate with scanning and transmission electron microscopy observations, and it is possible to rationalize the interaction among microstructure, abrasive, and alloy deposition processes.