Halnn Superhard Materials Co.

,Ltd

The classification of Surfacing from Halnn Superhard

With the development of modern science and technology, kinds of machinery equipments
develop forward to a direction with large-scale, high-efficiency, high-quality, the
requirement of the machinery products reliability and economy had increased higher.
Surfacing is an economic and fast way for the material to change the surfaces
performance, and can increase the products performance, extend the life, reduced the
cost, so widely used in various industry for manufacturing and repairing the parts.
Part 1 The characteristics and application of the surfacings technology:
Surfacing is the process which melting a certain performance material and covering this
on the surface of work piece. The difference between surfacing and welding is: surfacing
is changing the performance of the work piece surface instead of contacting the work
piece, so that getting a cladding layer which was wear-resisting, heat resistant, corrosion
resistant and other special performance, repairing the work piece which wear serious or
damage by wrong processing.

Characteristics of Surfacing:
(1) The combination between surfacing layer and base metal is metallurgical combine, the
combination has a high strength, good impact resistance;
(2) the metal composition and properties of the of deposited can adjust conveniently; the
commonly SMAW surfacing electrode and flux-cored electrode are convenient to adjust
formula, we can design a variety of alloy system to adapt to different working conditions.
(3) surfacing layer has a thick thickness, generally it is more suited to severe wear
conditions when surfacing layers between 2 to 30mm.
(4)Lower cost
(5) Since the surfacing technology is to increase the size or recovery of parts by welding,
or make the work piece surface getting an alloy layer with specific properties, so it is easy
to operate for the staff who was good at welding technology. It was widely used for parts
repairing and manufacturing in metallurgy, mining, electricity, agriculture, oil and other
industries.

There are many surfacing ways, now we will explain the classification and industry
product which can be used of surfacing.

Part 2 The classification of welding technology:

A. Surfacing technology is one technology of welding, so all welding can be instead of by
surfacing.
B. The classification of commonly surfacing according to its achieving conditions

www.halnntools.com

Halnn Superhard Materials Co.,Ltd

(1) Oxy-acetylene flame surfacing: As its flame doesn't have a very high temperature
(about 3100), and you can adjust the flame energy rate, you can get a low dilution rate
(1% to 10%) and a thin layer of surfacing, general using the carbon flame welding, the
amount of acetylene related to the welding metal. Advantage: simple equipment, low cost
and flexible operation, etc., was widely used. Disadvantage: labor-intensive, low
productivity. Therefore, this welding method is mainly used for manufacturing and
repairing the small parts, such as roller cone of oil wells drill, steam valves, engine valves
and farm machinery part. In addition to welding oxyacetylene flame is not just only used
for surfacing, but also applied to the spray, spray melting and other processes.

(2) Arc surfacing with electrode (as shown below): means process arc surfacing with
operating the electrode by hand,is one of the main method of surfacing. Characteristics:
simple equipment, lightweight, versatile, suitable for welding at the spot;
can be welded under the welders observed directly and operate, it is flexibility especially
for some shapes are not poor;
low productivity, poor working conditions, high dilution rate, will lead to the surfacing
layer hardness and wear resistance decreased. Currently mainly used for small batch
production or repair worn parts. Such as disc, mud pumps, shovels, roller for milling
cement raw material and other parts surfacing.
Surfacing layer hardness of arc surfacing with electrode: Different electrodes model has
the different hardness with surfacing layer, D638 high chromium cast iron surfacing
electrode, surfacing hardness HRC56; D707 tungsten carbide surfacing electrode Model:
EDW-A-15 surfacing hardness HRC60 ,etc.
(3) Self-shielded open arc surfacing: without protection of flux, just setup a screen
around the welding tip to protect operators eyes, the arc is visible, commonly welding
materials are flux-cored. Advantages:
high efficiency, able to adapt surfacing remanufacturing requirements which with
high-quality, high efficiency.
easier to control the temperature, so that the workpiece can get better wear resistance.
deformation can be controlled to a narrow range, difficult to cause deformation and
cracking of the base material.
this surfacing method has a strictly requirement to the process performance of welding
machine ,in case of increasing the welding spatter. This surfacing main used in process
the machine which was strictly on the wear resistant. Such as: coal mineral, kinds of
rolls, valves of nuclear power and other parts surfacing.
Hardness of surfacing layer: Different models of flux cored wire , surfacing layer hardness
is also different, such as the hardness of HB-YD115 model which was for surfacing layer
of high-manganese is HRC50-55, HB-YD351 model which for continuous casting roll
surfacing layer is HRC38-42.

www.halnntools.com

Halnn Superhard Materials Co.,Ltd

(4) Submerged arc surfacing (as shown below): means the arc which occurred between
the surfacing material and base material separated contacted the positive and negative
poles of the welding power ,was burried by the granular flux which was spread well
advanced and be front of the arc. Submerged arc surfacing has the following
characteristics:
high production efficiency;
surfacing layer has a good quality;
good working conditions;
transport more calories to work piece than other surfacing method ,and has a higher
dilution rate, usually need surfacing 2-3 layers in order to ensure the required
performance;
As it is based on the granular flux to form the protect condition, this surfacing just
onle used for surfacing on a horizontal position. Used for the work piece which was
cylindrical or have a big surface. Submerged arc welding is mainly used for strengthen
and repair the surface of the large, medium-sized work piece, such as rollers, wheel rim,
crank, chemical containers and reactor vessel linings, etc.
The hardness of surface layer which used submerged arc surfacing: Different submerged
arc wire models have different hardness, such as HB-YD327A (Q) HRC55.
(5) Plasma arc surfacing: its temperature was so high that can surfacing the material
which was difficult to melt, and can improve the surfacing speed, the lowest dilution rate
can reach to 5%, thickness of surfacing layer was 0.5-8mm, width was about 3 -40mm,
this method has a low dilution rate, surfacing with high deposition rates ; but a higher
equipment costs, there is a strong ultraviolet radiation and ozone pollution in space during
surfacing. So protective measures needed to do. Commonly used in the mass production
with high quality requirements.

(6) Electroslag surfacing: The deposition rates of electroslag surfacing is highest. The
plates can reach to 150kg / h, and can surfacing a great thickness just one time, therefore
the dilution rate is not high. The connector was so hot that heat treatment was needed
after surfacing. In addition, the surfacing layer can not be too thin (generally thicker than
14-16mm), otherwise can not establish a stable electroslag process.
Therefore, electroslag surfacing is mainly used for the parts which need a thicker
surfacing layer, the large and medium-sized parts which have a simple shape of surface.

we can make the work pieces surfacing more wear-resisting, heat resistant, corrosion
resistant and other special performance, than get the characteristic about higher hardness,
better abrasion resistance and impact resistance.
Then one trouble is coming, how can machining well when we process the surfacing parts.
Next article we will continue to analyze this case. Just click
http://halnntools.com/jjfa/140.html
www.halnntools.com