TECHNOLOGY-1

Technology Development for Hardfacing of

Large Components using Ni base Hardfacing Alloys
n EXECUTIVE SUMMARY
Systematic study on the effect of dilution from base metal on hardness and wear properties of Ni base hard facing alloys
have shown that dilution adversely affect the properties of this alloy. Further, a comparison of plasma transferred arc
(PTA) and Gas Tungsten Arc Welding (GTAW) process for hardfacing using these alloys showed that, dilution is
consistently high in the latter while it can be controlled easily in the former by suitable selection of the process variables. In
addition, PTA process is highly amenable for automation. Accordingly, PTA process is chosen for hardfacing of various
components of prototype fast breeder reactor (PFBR). Many intricate and large components of PFBR like grid plate sleeve
and large, bottom plate of grid plate assembly, have been successfully hardfaced using this process. Indian industries
actively collaborated with IGCAR and participated in the successful execution of these jobs.

750
700
650
600
550
500
450
400
350
300
250
200
150

Dilution
Deposit

316 L SS

WT-50
Colmonoy-5

-5 -4 -3 -2 -1 0 1 2 3

10

12

13

Fig. 1: Variation on hardness with thickness of deposit

N o rm a l L o ad
: 1 20 N
S li d i n g V e l o c i ty : 0 . 2 5 m / s
N e a r I n te r fa c e (0 . 1 5 - 0 .2 m m )
S i n g le la y e r
D o u ble la y er
0.016

0.012

0.008

0.004

0
0

450

900

1350

S lid in g d is tan ce (m )
Fig. 2:

170

11

Distance across the interface

Weight Loss (g)

Due to induced radioactivity

60
consideration arising from Co
isotope, it was necessary to switch
over from more widely used Cobased hardfacing alloys to cobalt free
alloys for hardfacing application in
various PFBR components. Ni base
hardfacing alloys, which have
already been used in various fast
breeder reactors worldwide was the
alternate material though
weldability of these alloys are poor
compared to Co based alloys. A
systematic study on hardfacing of
these alloys using GTAW process,
which was initially considered for
hardfacing based on wide experience
that existed with deposition of Co
based alloys using this process,
revealed that dilution from base
metal is considerably high if this
process is used for deposition of Ni
base alloys. Studies also revealed
that dilution has considerable effect
on hardness (Fig. 1) and wear
resistance (Fig. 2) of the deposits.
Further, significant variation in
microstructure of the deposit with
increase in dilution from the base
metal was also observed. The
adverse effect of dilution on the
deposit existed even up to 2 mm from
the fusion boundary, the desirable
maximum thickness recommended
for the hardfacing coating on various
PFBR components. Further, GTAW
process is not easily amenable for
automation. Hence, PTA process,
which is highly amenable for
automation was considered for
depositon. Studies on deposits made
by this process showed that it is
possible to considerably reduce
dilution in thse deposit by careful
choice of deposition parameters
(Fig.1).

Hardness, VHN10kg

n OUTLINE

1800

Variation of wear loss versus sliding distance for a) Interface (maximum

dilution) b) Surface of the first layer deposit and c) Surface of the two layer
deposit (dilution minimum)

TECHNOLOGY-1
n ADDITIONAL INFORMATION ABOUT THE PROCESS
Using information generated on systematic study of dilution during GTAW deposit, a procedure for fabrication bushes
made from the Ni base hardfacing alloy was developed which involved weld build up and precision machining. The bushes
made by this procedure met all the requirement and this procedure is now being adopted for fabrication of the bushes
made of this material to meet the requirement of PFBR. Figure 3 shows various stages involved in the design.

n GENERAL EXPLANATION RELATED TO THE DESCRIPTION

Using PTA process, various components
of PFBR have been hardfaced
successfully. They include diameter grid
plate sleeves (where hardfacing has to be
carried out in the inner surface of 80 mm
ID tube at depth of more than 500 mm
from one end of the sleeve) and large
component like bottom plate of grid plate
(diameter of 6.2 m) assembly. In the case
of former a small PTA torch which can
pass through the sleeve was indigenously
developed and in the case of latter,
automation of the deposition process
considerably reduced the number of
overlaps in the deposit which were the
potential locations for cracking. It was
also necessary to demonstrate that
distortion of the components during
hardfacing is kept well within the
machining allowance available. By
continuous improvement in process
parameters, design and quality controls,
all these requirements were successfully
met. Figure 4 shows the hardfaced
bottom plate of the grid plate assembly
fabricated during technology
development. This was made possible by
the constant interaction between design
and welding engineers at IGCAR and
industries that actually fabricated the
components and carried out the
hardfacing operation.

a)

b)

c)

Fig. 3 : Various stages involved in the fabrication of bushes using weld

deposition by GTAW process a) Stainless steel rod chosen for weld
deposition, b) rod after deposition, c) bushes after machining

Fig. 4 : Bottom plate of grid plate assembly after hardfacing during technology
development

n ACHIEVEMENT
1.
2.
3.

Choosing the optimum deposit thickness considering dilution from base metal, deposition process, distortion of the
components and machining allowance available
Development of procedure for hardfacing of various PFBR components
Technology development for fabrication of bushes made of hardfacing alloys using weld deposition technique

n PUBLICATIONS ARISING OUT OF THIS STUDY AND RELATED WORK

1.
2.
3.

C.R. Das, S.K. Albert, A.K. Bhaduri and G. Kempulraj, J. Mater. Process. Tech., 141 (2003) 60.
C.R. Das, S.K. Albert, A.K. Bhaduri, C. Sudha, and A.L.E. Terrance, Surface Engineering, 21 (2005) 290.
C.R. Das, S.K. Albert, A.K. Bhaduri and Nithya Ravindran, Materials Science and Technology (In Press).

Further inquiries:
Dr. A.K. Bhaduri, Materials Technology Division
Metallurgy and Materials Group, IGCAR, e-mail: bhaduri@igcar.gov.in

171