manufacturer of cobalt & nickel based hardfacing & wear ......system. some of the comm on...

Manufacturer of Cobalt & Nickel Based Hardfacing & Wear Resistant Alloys

PA RT N E R S I N W E A R S O LU T I ON S

www.weartech.net

Industries worldwide are being met with in creased

de mands for efficient, timely delivery of their prod -

ucts. This is only possible if the equipment being

used has component parts that are effective, long

lasting, and eco nom i cal. Weartech In ter na tion al was

found ed in 1990 aiming to use its tech ni cal and prac -

ti cal know-how to offer its cus tom ers so lu tions to

their wear prob lems. With over 150 years of com -

bined ex pe ri ence, the col lab o ra tive ef forts of the

Weartech team enable it to be a leader in man u fac tur -

ing ex per tise, alloy de vel op ment, en gi neer ing, and

ap pli ca tion technology. Fur ther more, Weartech is

com mit ted to being a pow er ful force in the mar ket

through excellence in service, quality and tech nol o gy.

As you leaf through this brochure, we are sure that

you will find Weartech International to be the choice

for re li able wear resistant prod ucts. We are a step

ahead of the com pe ti tion. Al low us to be your part -

ner in wear so lu tions.

Table of Contents

Weartech Alloys........................

Technical Data..........................

Product Forms

Hardfacing Alloys

•Rods, Electrodes, Wires, & Powders..•Product Dimensions.......................Wear Resistant Alloys

•Components.................................•Forms and Sizes Available...............

Quality Control.........................

Welding Techniques.................

Other Products & Services......•Tungsten Carbide Tubular Rods•Master Alloys•Custom Hardfacing•Welding Equipment

Industries We Serve..................

The Weartech Team..................

6

9

10

11

13

14

19

20

21

12

3

WEARTECH INTERNATIONAL

Why Hardface?

Hardfacing is the pro -

cess by which a wear

re sis tant hard sur face

is de pos it ed onto a

com po nent by weld ing

in order to increase its

useful life. Hardfacing

is carried out when

equip ment parts are to

be subject to abra sion,

corrosion or impact at

room or elevated tem-

pratures, in order to

improve the part’s wear

resistance, strength

and hardness thus increasing efficiency.

Moreover, hardfacing keeps the parts in bet ter

con di tion, reducing part re place ment, pow er

con sump tion, and equip ment down time costs.

Weartech Co balt and Nick el

Base Alloys

Proven to be the most ver sa tile of hardfacing

al loys, Weartech’s co balt- and nick el- based

al loys are spe cial ly formulated to re sist a wide

range of hos tile en vi ron ments in clud ing

abra sion, cor ro sion, gall ing, ox i da tion and

ero sion. They are able to main tain their hard -

ness at tem per a tures of up to 1500°F (800°C)

and have been prov en

to be use ful in in dus -

tries rang ing from

aero space to petro

chemical. The com-

pounds in the struc -

ture of Weartech

al loys that con trib ute

to wear and ox i da tion

re sis tance vary acco-

rding to the alloy

sys tem. Some of the

com mon alloy sys tems

Weartech of fers are

Co-Cr-W, Co-Cr-Mo,

Co-Mo-Si, Ni-Cr-B,

and Ni-Cr-Mo.

Weartech’s Tech ni cal

Ser vice De part ment will work close ly with you

in selecting alloys that will solve your wear

prob lems.

Weartech Dental

Al loys

Weartech manufactures dental alloys in a

number of alloy systems such as Co-Cr-Mo,

Co-Cr-Mo-W, Co-Cr-Fe-Mo, and Ni-Cr-Mo.

These alloys are supplied as starting stock

rod, ground rod, and cut and polished dental

ingots. Please contact us for more information

on these products.

3

Weartech Alloys

Our Al loys

Seat rings being hardfaced by Weartech’s AutoTig 2000.


4

Weartech Hardfacing & Wear Re sis tant Al loys

Alloys Specs Nominal Chemical Composition (wt %) RC

C Cr Co W Ni Fe Si Mo Other Hardness

Ultimet® and Hastelloy® are registred trademarks of Haynes Intl., Inc.

Norem is a registered trademark of Electric Power Research Institute.

Colmonoy is a registered trademark of Wall Colmonoy.

C

O

B

A

L

T

N

I

C

K

E

L

I

R

O

N

WT-1 ERCoCr-C 2.3 30 Bal. 13 < 3 < 3 0.8 48 - 59

WT-3 2.4 32 Bal. 13 < 3 < 3 1 51 - 63

WT-4 0.8 30 Bal. 14 < 3 < 3 1.5 44 - 50

WT-6 ERCoCr-A 1.1 28 Bal. 4 < 3 < 3 1.1 38 - 48

WT-6H 1.3 30 Bal. 5.5 1 1 1.3 42 - 48

WT-12 ERCoCr-B 1.4 29 Bal. 8 < 3 < 3 1.5 44 - 52

WT-12H 1.7 29 Bal. 8 < 3 < 3 1.5 44 - 54

WT-19 1.7 31 Bal. 10 < 3 < 3 1 48 - 60

WT-20 2.5 32 Bal. 17 < 3 < 3 1 Max. 50 - 60

WT-21 ERCoCr-E 0.25 27 Bal. 2.5 < 3 1 Max. 5 27

WT-25 0.1 20 Bal. 15 10 < 3 1 16 - 24

WT-31 0.5 25 Bal. 8 10 2 1 21

WT-32 ERCoCr-F 1.7 26 Bal. 12 23 < 3 1.4 32 - 46

WT-190 ERCoCr-G 3.2 26 Bal. 14 <3 < 3 50 - 62

WT-306 0.4 25 Bal. 2 5 Nb 6 36

WT-400 0.08 8 Bal. 2.6 29 51 - 58

WT-694 PWA 694 0.9 28 Bal. 19 5 < 3 V 1 47 - 54

WT-800 0.08 17 Bal. 3.5 29 54 - 62

Ultimet ® 26 Bal. 2 9 3 5 30

WT-40 RNiCr-A 0.4 11 Bal. 2 2.2 B 2 35 - 45

WT-50 RNiCr-B 0.6 13 Bal. 4 3.7 B 3 45 - 56

WT-56 0.6 12.5 Bal. 3.3 3.3 B 2.7 50 - 58

WT-60 RNiCr-C 0.7 14 Bal. 4.5 4 B 3 54 - 62

WT-700 0.08 15 Bal. 3.5 32 42 - 48

WT-C AMS 5388 0.12 16 Bal. 5.5 0.8 17 Mn 0.8, V 0.3 20 - 26

WT Ni-60 0.4 16 Bal. 20 3 30

WT 45 0.5 14 Bal. 4.5 4.5 B 2 53

Norem-02A 1.25 25 4 Bal. 3.3 2 Mn 4.5, N2 < 0.06 36 - 42

Norem-04A 1.1 22 4.5 Bal. 2.5 1.9 Mn 3.7, N2 < 0.1 37 - 40

Norem-04B 1.1 22.5 4.5 Bal. 2.8 1.9 Mn 4.5, N2 < 0.1 32 - 36

Ni-Res A-439-83 2.55 1.3 29 Bal. 0.05 160 RB

WT-590 Superwear 4.2 25 11.3 1.5 Bal. 1 8.5 58

WT-595 4.2 30 Bal. 2.2 Mn 4.2 58


5

Weartech Hardfacing & Wear Re sis tant Al loys

Note : Applications indicated are a few examples. Materials must be tested under actual service con di tions to

determine their suitability for a particular purpose.

Available Forms

R E C W P

Applications Alloys

Seaming rolls, valve seats, wear pads, pump sleeves, seals, bearings, bushings, saw blades, cutters WT-1

Steel mill guide rolls, forming rolls, bushings, seal rings WT-3

Battery mold, guide rolls for galvanizing tanks WT-4

Engine Valves, Pump shafts & sleeves, hot cutting & rotary knives, high pres.-high temp. valves, extrusion screws WT-6

Same as WT-6 WT-6H

Extrusion dies, scissor blades, saw blades, guide bars, wood cutting tools, pump sleeves, twist rolls, knives WT-12

Saw blades and tips, wood cutting tools WT-12H

Guide rolls, thrust bearing shoes, ball bearing races WT-19

Marine engine valves, control valves for petrochemicals, steel mill rolls, homogenizer valve components WT-20

Hot trimming & forging dies, high pres.-high temp. valves, hot shears, valve seats, pump impellers, rings WT-21

WT-25

WT-31

Engine Valves and Seats WT-32

Tri-Cone Rock Bits for Oil Drilling WT-190

WT-306

Bearings (Journal or Sleeves) WT-400

WT-694

Magnetic tape heads, valves, extruder barrels WT-800

Components subjected to corrosion and moderate wear Ultimet ®

Glass industry plungers and mold components WT-40

Liners, thrust shoes, bushings, cages and other valve components for nuclear applications WT-50

Plastics extrusion screws WT-56

Pump sleeves WT-60

Nuclear applications WT-700

Seals, sleeves and dies, plastic extrusion, agitator bearings, pump impellers, ball valves WT-C

Engine valves WT Ni-60

WT 45

For cobalt-free components in nuclear applications, valves Norem-02A

For cobalt-free components in nuclear applications, valves Norem-04A

For cobalt-free components in nuclear applications, valves Norem-04B

Ni-Res

WT-590

WT-595

R Rods

E Electrodes

C Cast and Machined Components

W Wires

P Powders


Technical Data

Hot Hardness of Weartech Alloys

Relative Wear Performance of Weartech Al loys

6

Alloys

Type of Wear

Metal-to-Metal

Impact

Erosion

Corrosion

Cold Abrasion

Hot Abrasion

Excellent

Good/Moderate

Not Recommended

WT-1

WT-6

WT-12

WT-20

WT-21

WT-32

WT-190

WT-694

WT800

WT-40

WT-50

WT-60

Norem2A


7

Technical Data

Mechanical Properties

Physical Properties

HT - Heat Treated AC - As Cast

WT-1 48- 59 AC 70,000 0 - 1 AC 4

WT-6 38 - 48 AC 115,000 0 - 1.5 AC 9

WT-12 44 - 52 AC 76,000 0 - 1 AC 7

WT-20 50 - 60 AC 60,000 0 - 0.5 AC 3

WT-21 27 HT 101,000 1 - 3.5 Better than 6

WT-25 16 - 24 HT 155,000 – Better than 6, 21

WT-32 32 - 46 NA – Better than 6

WT-190 50 - 62 NA 0 - 1 AC < 4

WT-694 47 - 54 NA 0 - 1 AC < 4

WT-800 54 - 62 – – AC < 4

WT-40 35 - 45 – – NA

WT-50 45 - 56 – – NA

WT-60 54 - 62 – – NA

Alloy Hardness Tensile Strength % Elongation Impact Strength

RC (PSI) RT RT, ft/lb

WT-1 8.73 0.315 1259 2300 0.095 7.6

WT-6 8.39 0.303 1292 2360 0.101 9.1

WT-12 8.53 0.308 1286 2350 0.098 8.4

WT-20 8.73 0.315 1259 2300 0.093 7.6

WT-21 8.31 0.300 1364 2490 0.101 7.6

WT-25 9.13 0.330 1409 2570 0.092 9.1

WT-32 8.85 0.320 1300 2375 0.101 8.1

WT-190 8.67 0.313 1234 2255 0.093 7.6

WT-694 9.04 0.326 1273 2325 0.092 7.6

WT-800 8.72 0.312 1352 2465 0.098 7.3

WT-40 8.30 0.299 1010 1850 0.100 8.6

WT-50 8.14 0.294 1065 1950 0.110 8.4

WT-60 7.80 0.280 1038 1900 0.100 8.1

Alloy Density Liquidus Specific Heat Thermal Expansion

g/cc lb/in °C °F BTU/lb °F µin/in °F3


8

Technical Data

Finishing of Weartech Alloys

Machining: Turn ing, facing & boringTools Recommended : C-2 or Carboloy 883

DOC: Depth of Cut IPR : Inches per Revolution SFPM : Surface Feet per Minute

Note : for drilling use carbide tools

GrindingGrinding is recommended for alloys with hardnesses higher than RC 55. The alundum

type of wheels is preferable. Grinding speeds of 2800-4000 ft/min are used de pend ing on

the alloy and parts. The use of coolants minimizes surface cracks.

Cor ro sion Re sis tance

The comparative

corrosion re sis -

tance of various

Weartech al loys is

shown in the table.

Al most all the al -

loys show good re -

sis tance to ace tic,

for mic and phos -

pho ric ac ids. In all

cases, ac tu al field

tests are rec om -

mend ed pri or to al -

loy se lec tion.

AlloySulfuric Acid

Conc. 5-10%

Nitric Acid

Conc. 25-65%

Temperature Range

Hydrochloric Acid

Conc. 5.65%

RT 150ºF RT Boiling RT Boiling

WT-1

WT-6

WT-12

WT-20

WT-21

WT-32

WT-190

WT-694

WT-800

WT-60

<5 mils/year >20 mils/year >50 mils/year >400 mils/year

Alloy

WT 6,50

WT 1,12

WT 3,19,60

WT 12

0.25

0.25

0.25

0.25

0.003-0.006

0.002-0.005

0.002-0.004

0.005-0.008

40-50

35-45

35-45

50-60

Rough Machining

IPR (in/rev) SFPMDOC (in)

Semirough Machining

0.125

0.125

0.125

0.125

0.004-0.008

0.003-0.007

0.003-0.005

0.006-0.010

50-60

55-65

55-65

60-70


Semirough Machining

0.005-0.025

0.005-0.025

0.005-0.025

0.05-0.025

0.006-0.012

0.005-0.010

0.003-0.007

0.007-0.012

70-90

65-85

65-85

80-90



WEARTECH INTERNATIONAL 9

As a man -u fac tur er ofwear re sis -tant alloyc o n s u m -ables (rods,elec trodes,wires andpow ders )and com -p o n e n t s ,We a r t e c hfor mu lat esits productsusing soundmet al lur gi calprin ci ples to of feryou and your cus -tom ers products withex cel lent per for mance.

Rods&Electrodes Weartech International is a lead ing

man u fac tur er of co balt- and nick el- base

hardfacing rods and elec trodes. Our rods

are produced us ing state-of-the-art

com put er con trolled hor i zon tal con tin u ous

cast ing sys tems. Avail able in a wide range

of lengths and di am e ters, Weartech rods

are produced in both stan dard and

cus tom ized com po si tions to meet your

spe cif ic wear re quire ments.

Weartech’s electrodes de pos it quick ly, with

excellent weldability and slag removal,

producing smooth, sound deposits. These

electrodes can be applied using either AC

or DC cur rent. How ev er, DC re verse

po lar i ty is the pre ferred method.

WiresW e a r t e c h ’ s

met al cored

tu bu lar wires

are man u fac -

tured for Gas

Met al Arc

Weld ing dep -

o si tion and

are suit able

for au to mat ic

and semi-au to -

mat ic ap pli ca -

tion. The weld ed

de pos its have

higher silicon and

man ga nese contents

than cast rod de pos its,

giving bet ter deox i diza tion

and weld ing char ac ter is tics

with out jeop ar diz ing wear resis-

tance. Base met al di lu tion can be con -

trolled by using spe cial pow er sup plies

such as a pulsed arc.

PowdersWeartech of fers gas-atomized hardfacing

al loy pow ders. The par ti cle shape is gen er al ly

spherical and a well controlled sieve

analysis en hances flow char ac ter is tics.

Weartech’s powders produce clean sound

desposits due to low gas contents. Our

metal pow ders are avail able in a wide

range of dif fer ent sieve analyses to suit

various application methods.

Prod uct Forms


10

Available Diameters : Rods & Electrodes

Solid Wires in diameters 0.045” (1.2 mm), 0.062” (1.6 mm), and 0.078”

(2.0 mm) are available in WT-1, WT-6, WT-12, WT-21, WT-25, and WT-31.

Lengths availableRods are available from 14 inches (350 mm) to 12 feet (approx. 4 meters). Rods of

longer lengths can be supplied on a special order basis.

Available Diameters : Wires

Wires are available in 25 lb or 15 kg spools.

Dia. 3/32” 1/8” 5/32” 3/16” 1/4” 5/16” 3/8”

Alloy 2.6 mm 3.2 mm 4.0 mm 5.0 mm 6.4 mm 8.0 mm 10 mm

WT-1

WT-6

WT-12

WT-20

WT-21

WT-32

WT-190

WT-694

WT-800

WT-40

WT-50

WT-60

Norem02A

0.045”1.2 mm

0.062”1.6 mm

0.093”2.4 mm

Cobalt-based Alloys

Dia.Alloy

WT-40

WT-50

WT-60

WT-C

0.045”1.2 mm

0.062”1.6 mm

0.093”2.4 mm

Nickel-based Alloys

Available Grades of PowdersPTA, Spray and Fuse, Plasma Spray, and HVOF

Note: Rods are supplied either as cast or surface ground.

Dia.Alloy

WT-1

WT-6

WT-12

WT-21

Product Di men sions


11WEARTECH INTERNATIONAL 11

Pouring of a molten Weartech

al loy into a centrifugal caster

mold to make a valve com po -

nent (above). Bar stocks and

parts machined from bar stocks

in Weartech’s machine shop

(right).

Product Forms: Com po nents

Solid Bar StocksWeartech uses and supplies solid bar

stocks to produce engineered parts

made of cobalt- and nickel- based

Weartech alloys. Shafts, sleeves, rings,

and other components are produced

from solid bar stocks where total

mechanical integrity is of paramount

importance. Cast bar stocks offer bet-

ter wear-resistance with reduced

machinability whereas the wrought

bar stocks offer improved machinabil-

ity and mechanical properties.

Why Components?While hardfacing a ma chine part does en hance its

strength and du ra bil i ty against wear, many compo-

nent designs do not lend themselves to hardsurfacing.

A num ber of engineering de signs not only pre fer but

also de mand, com po nents to be made en tire ly from

wear re sis tant al loys in or der to improve wear

per for mance.

Wherever machinery is subject to extreme abra sion,

cor ro sion, impact and temperature, you will find

Weartech’s component parts. Various Orig i nal

Equipment Manufacturers (OEM) specify them to

build ex cel lent wear life into valves, pumps,

me chan i cal seals, bearings, seats, and numerous

oth er parts.

Weartech offers high quality components made from

different types of starting stocks--centrifugal

cast ings, solid cast bar stocks, solid wrought bar

stocks, and investment castings.

Centrifugally Cast PartsParts produced by centrifugal casting are dense, sound and

have a fine grain structure in comparison to stat ic and

in vest ment cast parts. In this method of casting, a cen trif -

u gal force is exerted on the molten metal whilst it is poured

into a cylindrical mold spinning on its axis. Chill crys tals

form uniformly at the mold-metal in ter face. So lid i fi ca tion

con tin ues pushing ox ides, im pu ri ties, and gas es to wards the

core that is later bored out leaving behind a dense casting.

Components

Wear resistant alloy parts cast and machined to print.


WEARTECH INTERNATIONAL12

Product Forms: Com po nents

Investment CastingsInvestment casting is also known as the lost wax process.

A wax impression is coated with various ceramic materi-

als and then replaced with the chosen alloy to create an

exact replica of the initial wax pattern.

The advantages of this casting process over others

include flexibility of design, close tolerances, thin

sections, and high static and dynamic mechanical

properties. The use of this process tends to produce a

good surface finish with lower total component cost.

Weartech manufactures investment castings of cobalt-

and nickel- based alloys to customers’ specifications.

MachiningComponents can be supplied either as rough machined

or finished machined parts. Weartech has a fully

equipped machine shop that is able to perform a wide

variety of machining and finishing operations using state-

of-the-art CNC lathes. With the capability to produce

both simple and complex parts, Weartech’s machining

department offers excellent quality and on-time delivery

at a competitive price.

Centrifugal Casting Investment Casting

Horizontal VerticalMin (in) Max (in) Min (in) Max (in)

OD, (in) 1/2 10 2 18 26 Max

ID, (in) 1 9 1 16 0 (Solid)

Length, (in) 14 24 1/2 8 50 Max

Weight, (Lb) 20 300 1 200 120 Max

Wall thickness NA NA NA NA 0.080 in and thicker

Weartech Alloys Available: Cobalt-based: 1, 4, 6, 12, 3, 19, 20, 21, 31, 800 Nickel-based: 40, 45, 50, 60, C, 273, Ni Resist

Other Alloys Available: Ultimet®, Nickel and Cobalt based Air Melt Super Alloys

Manufacturing Capabilities - Castings

Bar Stock Availability

Cast Bar Stock Wrought Bar Stock

Diameter (in)

Max Length (in)

WT Alloys Available

1/2 to 4

8

1, 6, 12, 21, 3, 25,

31, 40, 45, 50, C

1/2 to 4

48

6B

1.-Drawing or Sketch2.-ID, OD and Length3.-Tolerances4.-Material--Spec-i-fi-ca-tions5.-Finishes-

6.-Quantity7.-Delivery---Requirements8.-Quality Control---Specifications

Quotation Checklist


Specifications : •AWS A5.13-2000 ECoCr-A, B, C, E •AWS A5.21-2001 ERCoCr-A, B, C, E, F, G•AWS A5.21-2001 ERCCoCr-A, B, C, E•AWS A5.21-2001 ERNiCr-A, B, C•ASME SFA 5.13 & SFA 5.21•AMS 5382, 5385, 5387, 5388•AMS 5788, 5789, 5796, 5797, 5894•SAE J775 (VF3, VF5, VF6, VF7)

•MIL-R-17131C •MIL-C-24689 Comp 20, 21, 22, 23 •MIL-C-24248 Comp I, II, III, IV •MIL-DTL-24422 Comp A & B•UNS R30001, R30002, R30006, R30103•UNS R30012, R30016, R30021, R30605•UNS W73001, W73006, W73012, W73021•UNS W73031, W73036, W73041, W73042


Weartech’s standard is the result of a company-

wide philosophy of quality awareness and control.

From the purchasing of raw ma te ri als to the pack -

ag ing of the prod uct prior to ship ment, Weartech

ex er cis es strict qual i ty standards that con form to

or sur pass those of the in dus try.

All Weartech al loys are manufactured us ing top-of-

the-line, pre-test ed and quality ap proved raw

ma te ri als. First made as mastermelts, our al loys

are manufactured using met al lur gi cal ly tested

melt practices that en sure high quality alloys with

low percentages of gas and oth er trace elements

that affect weldability.

Moreover, only pre-

approved mastermelts are

used in the man u fac tur -

ing process en suring

con sis ten cy in product

com po si tion and weldabil-

ity from the be gin ning to

the end of the heat.

Representative sam ples

from each heat are retest-

ed for chemical com po si tion, weldability, de pos it soundness and hard ness. LPI tests are also per -

formed on the weld de pos its. Mi cro struc tur al anal y ses of de pos its, al loy ver i fi ca tion and me chan i -

cal testing are per formed by request.

Weartech has al ways maintained a high stan dard of quality and continues to implement

in-process quality control procedures to manufacture high grade products. Our quality sys tem

con forms to the ISO-9002 pro gram. Prod ucts are man u fac tured to a number of specifications

including those listed in the table below.

13

Quality

Quality...Weartech’s Stan dard

Quality Policy -- Weartech International is com mit ted topro vid ing consistently high qual i ty prod ucts and services that meet or

ex ceed in dus try standards, contractual re quire ments and cus tom er

ex pec ta tions.

The com plete in spec tion of all of our products is

a standard part of our quality control sys tem,

and em ploy ees support the above policy by par -

tic i pat ing in our quality program and work ing

con tin u ous ly to im prove the products and ser -

vic es provided by Weartech.


14

Welding Tech niques

Welding Techniques

Recommended Welding Procedures for Weartech Alloys

Hardfacing : An Over viewHardfacing is the pro cess of de pos it ing a wear resistant alloy

material on a metal part by weld ing to form a protective surface

which resists abrasion, heat, corrosion, cav i ta tion and other

types of wear. There are three types of welding used with rods

and electrodes – oxy-acetylene (O-A), gas tungsten arc (GTA),

and shielded metal arc (SMA). Gas metal arc (GMA) welding is

used for wires while plasma transferred arc (PTA) is used for

powder consumables.

Alloy

WT-1

WT-6

WT-12

WT-20

WT-21

WT-32

WT-190

WT-694

WT-800

WT-40

WT-50

WT-60

Norem2A

O-A GTA SMA GMA PTA

Good

Not Available

Not Recommended

O-A denotes Oxy-Acetylene

GTA denotes Gas Tungsten Arc (TIG)

SMA denotes Shilded Metal Arc (MMA)

GMA denotes Gas Metal Arc (MIG)

PTA denotes Plasma Transferred Arc


Getting Ready to Hardface

The base metal surface that is be ing

hardfaced must be free of rust, dirt, scale, oil,

grease and other foreign materials to pre-

vent po ros i ty in and crack ing of the

de pos it. Grit blast ing, steam clean ing,

grind ing, machining and wire brush ing are

all rec om mend ed meth ods of pre par ing the

base met al.

Good base metal prep a ra tion and prop er pre -

heat ing and postcooling procedures (see chart)

are vital to produce sound deposits. Note: pre -

heat ing manganese steels is not rec om mend ed

but the part should be brought to room temper-

ature. The preparation is es sen tial ly the same

for different hardfacing tech niques.

Preheating and Postcooling

15

Low Carbon Steel (up to 0.40%C) for thin sections only

Low Carbon Steel (up to 0.40%C) for thick sections only

High Carbon Steel (over 0.40%C) for thin sections only

Low Alloy Steels (up to 10% alloy) for thin sections only

High Carbon Steels (over 0.40%C) for thick sections only

Low Alloy Steel (up to 10% alloy) for thick sections only

Air-Quench Steels

High Chromium-Nickel (Austenitic) Stainless Steels

(304, 309, 316, etc.) thin sections only

High Chromium-Nickel (Austenitic) Stainless Steels

(304, 309, 316, etc.) thick sections only

High Chromium-Nickel (Martensitic) Stainless Steels


High Chromium-Nickel (Ferritic) Stainless Steels


High Temperature Nickel Alloys

(400, 600, 601, 625, 718 etc.)

Base Metal Preheat Temp. Postheat

Not Required

ºF ºC

200-600 93-315 Slow-Cool

Slow-Cool

Slow-Cool

Slow-Cool

Maintain at 400º-600º F for 4 hrs.

per 1 inch thickness, then reduce heat

by 50º F (10º C) per hour till cool.

Maintain at 200º-600º F for 4 hrs.

per 1 inch thickness, then reduce heat

50º F (10º C) till cool.

Stress-Relieve

300-600 148-315

1100-1200 593-648

Not Required Not Required

200-500 93-260

400-600 204-315

200-600 93-315

200-500 93-260

Not Required Air-Cool

Air-Cool


16

Welding Techniques : Rods and Elec trodes

Gas Tungsten Arc (GTA, TIG)The Gas Tungsten Arc process generates localized heat and

avoids car bur iza tion from the flame. The process is adapt able

to both manual and automatic operation, and is clean and easy

to mechanize. This characteristic enables improved productivity

with lower capital investment than with PTA.

� Follow the same preparation and preheating/postcooling

pro ce dures as il lus trat ed previously

� Use direct current straight polarity

� Thorium-Tungsten electrode 3.2 to 4 mm diameter

� Argon flow 10 - 15 L per minute

� Typical base metal dilution is 5% to 10%

Recommended current settings are listed below.

Shielded Metal Arc (SMA, MMA)The most widely used welding process for on-site hardfacing,

Shield ed Met al Arc welding is versatile, more por ta ble, and

less cost ly than oth er welding processes. In this process, the

heat for weld ing is gen er at ed by an arc es tab lished between a

flux-cov ered consumable elec trode and the work.

� Follow part preparation and preheating/postcooling proce-

dures as men tioned pre vi ous ly.

� Use direct current, reverse polarity.

� Typical base metal dilution 15% to 25%.

See recommended current setting suggestions below.

Base Metal

Mild and Low Alloy Steels

1/8”3.2 mm

60-110 A

80-120 A

5/32”4.0 mm

90-130 A

100-140 A

3/16”5.0 mm

130-170 A

140-180 A

1/4”6.4 mm

170-220 A

180-230 AAustenitic Stainless Steels

Diameter

Electrode

Diameter

Current in Amperes

Direct Current Alternating Current

1/8” (3.2 mm)

3/32” (2.6 mm)

80-100 90-110

110-170

140-180

100-160

130-180

5/32” (4.0 mm)

3/16” (5.0 mm)

3/32”2.6 mm

50-100 A

60-110 A

50-80 60-90

230-280220-2701/4” (6.4 mm)


Weld ing Techniques: Rods & Electrodes

Oxy-Acetylene The Oxy-Acetylene process is the choice procedure to use to

minimize base metal dilution. Since the Oxy-Acetylene flame

temperature is much lower than that of an arc, melting the rod

and preheating the base metal is easily controlled.

� Sweat the surface of the part to be hardfaced

� Using the recommended flame, melt the rod and deposit it

on to the sweated surface (see flame adjustment chart

below)

� Typical base metal dilution should be less than or equal to

5%

Flame Ad just mentThe oxyacetylene flame has three sections – the inner cone, the

mid dle acet y lene feather, and the outer flame envelope. The

ratio of the length between the inner cone and the mid dle

acetylene feather should be con trolled by adjusting the gas es.

Torch tip sizes from #3 to #6 are used depending on the size of

the rod and size of the parts.

The surface of the base metal in the

im me di ate area being hardfaced is

brought to its melting temperature.

The hardfacing rod is melted and

spread over the surface of the base

metal thus form ing a new bonded hard

layer on the sur face of the base metal.

S

S

S S

co d

Hardfacing WT Alloy Recommended Flame

W T-1 3 x

W T-6 3 x

W T-12 3 x

W T-20 3 x

W T-21 GTA or SMA Welding

W T-32 3 x

W T-190 3 x

W T-694 GTA Welding

W T-800 GTA Welding

W T-40 1 x

W T-50 1 x

W T-60 1 x

17

ACETYLENE

FEATHER

(3x)

WELDING ROD

ACETYLENE FEATHER

MOLTEN PUDDLE

OUTER ENVELOPE FLAME

INNER CORE

OUTER ENVELOPE FLAME

ACETYLENE FEATHER


18

Process Comparison for Application of Hardfacing Alloys

BCR denotes Bare Cast Rod

Contact Weartech’s Technical Department to aid you in finding processes, consumables, and

equipment combinations that best serve your needs.

Welding Tech niques: Wires & Pow ders

Gas Metal Arc (GMA, MIG)Weartech’s cobalt-base tubular wires are continuous wires of

elemental powders wrapped in a cobalt sheath. Dur ing the

welding process, the strip and the powder melt to form an

alloy deposit under the arc. Base metal dilution is 20 - 30 %

Typical current and voltage set tings are given below.

Plasma Trans ferred Arc (PTA)The plasma transferred arc process is very similar to the gas

tungsten arc process. In the PTA process, the arc or plasma

is a brought into line with a narrow orifice which intensifies

and focuses the heat that is generated. Unlike the GTA

process where solid rods or wires are used, the PTA process

uses a pow der consumable. This process is widely used for

large parts. Typical base metal dilution ranges from 5 - 15%.

Other types of powders are available for spray

and fuse, plasma spraying and high velocity oxy-

fuel (HVOF) applications.

DiameterVolts Amps

Stickout

in mm in mm

0.045

1/16

3/32

1.2

1.6

2.4

18 - 20

19 - 22

24 - 30

170 - 200

200 - 220

270 - 320

1/2 - 1

1/2 - 1

3/4

12.7 - 25.4

12.7 - 25.4

19

Process Consumable Deposition

Thickness In.

Deposition

Rate (lb/hr)

Deposition

Efficiency (%)

Dilution

(%)

Automatic Deposition

Equipment Cost

O-A

GTA

SMA

GMA

PTA

BCR

BCR

Electrode

Wire

Powder

1/16-3/16

1/16-3/16

1/8-3/16

3/32

1/8 max

3-5

3-5

3-5

5-10

4-7

100

100

50

95

95

5 max.

5-10

15-25

30

5-15

$30,000

$30,000

N/A

$25,000

$120,000


19

Diameters of rods/electrodes avail able :

1/8”, 5/32”, 3/16”and 1/4”

Lengths : 14” & 28”

For other sizes contact Weartech.

Other Prod ucts & Ser vic es

Master AlloysWeartech has five in duc tion melt ing fur nac es that pro duce

cobalt- and nick el- base alloy mastermelts. Using only quality

assured raw materials and meltallurgically tested melting prac-

tices, Weartech’s ingots are made to ensure good flow character-

istics and sound castings. Each heat of master alloy is certified

for its chemical composition and other special re quire ments.

In gots are sup plied in weights of 15 (7 kg) and 25 (11 kg)

pounds.

Custom Hardfacing & Ma chin ingAmong other services, Weartech offers custom hardfacing of

com po nents of simple to moderate com plex i ty. Parts of various

sizes are hardfaced ei ther manually, or using Weartech’s

AutoTig 2000. After hardfacing, the com po nents are prop er ly

stress re lieved, heat-treat ed and then ma chined to your spec i fi -

ca tions. For further de tails, con tact our Cus tom er Ser vice

De part ment.

Tungsten Carbide Tubular ProductsWeartech offers a wide variety of tungsten car bide tubular rods

for oxy-acetylene, GTA and SMA welding ap pli ca tions. Wrapped

in a steel sheath, the tungsten carbide tubular rods are made of

carefully se lect ed carbide par ti cles so as to en hance its wear and

impact loads. The car bide fill is main tained at 60%.

AutoTig Welding Ma chineWeartech designs and manufactures Automatic Tig Welding

Systems for overlaying using bare cast rods of diameters rang-

ing from 3/32” to 3/16”. The sys tems are custom designed for

specific applications including automotive valves, seats, rings

and forging dies. For the economics of the Au to mat ic Tig

Weld ing System as opposed to other methods of weld ing, or for

fur ther de tails, con tact Weartech’s Cus tom er Service De part ment.

WT Alloy Mesh ofCarbide

Applications

Horseshoe Tungsten

Weartung 20/30

Weartung 30/40

Weartung 40 Dn

Wearfine

5 - 8, 8 - 10 Hardfacing horseshoes, mining

earth moving equipment parts,

(e.g. auger bits, bucket elevator

lifts), coal pulverizer rolls,

bucket teeth, sand crusher rolls

20 - 30

30 - 40

40 Dn

100 - 250


Industries We Serve

Industries We Serve

20

INDUSTRY APPLICATION WT ALLOY

Chemical & Petrochemical Pump & valve components

Seats, discs, gates, balls,

Plugs, seals, sleeves 3,6,12,20,21

Bushings, agitators 4, 6

Conveyor & extruder screws 6,12,60

Rockbits for oil drilling & mining 6, 190

Timber & Wood Cutting Chain saws, guide bars 6,12

Saw tipping 12, 12H

Knives & cutter rolls 12

Rotary feeders 6,12

Metal Forming Forging dies 6,21

Hot forming 6,21

Cold forming of metals 1,21

Extrusion dies 1,3

Automotive Internal

Combustion Engines Valve seats, cages and stems 1,6,20,32

(Petrol & Diesel)

Power Generation Steam valves, erosion shields 6

Valves & pumps 1,6,12,20,21

Ship Building Bearing & bushes 6

Food Processing Rendering screws 6,12,50

Can seaming rolls 1,6

Steel Mills Continuous cast rolls 6,20

Galvanizing rolls 4,6

Other rolls, bearings etc. 6,21

Hot shears 6,21

Sheet and scale breaker rolls 12

Rubber Mixers 6

Bodies 12

Brick & Tile Trimming dies 6

Battery Dry cell tooling 4

Glass Plungers, molds, preform

Blanks, neck rings 40,50,60

Sewage, Plastic extrusion

Oil extrusion Screws 1,6,12,56

Other Mechanical Seals 6, 12


WEARTECH INTERNATIONAL 21WEARTECH INTERNATIONAL

Notes

22

Notes


AGENT/DISTRIBUTOR:

USA

1177 N. Grove Street

Anaheim, CA 92806

USA

(714) 683-2430

1-877-Weartech

(714) 683-2500 Fax

[email protected]

EUROPE

Moor Road

Baglan Industrial Estate

Port Talbot

SA12 7BJ

United Kingdom

+44 (0) 1639 814 907

+44 (0) 1639 814 672 Fax

[email protected]

manufacturer of cobalt & nickel based hardfacing & wear ......system. some of the comm on...

Documents