PROTECTIVE LAYERS

Contents
1. Corrosion resistant clad steel ............................................................................................... 13
1.1 Examples of clad plates ......................................................................................... 13
1.2 Advantages of clad plates over high-alloyed solid plates ....................................... 14
1.3 Production of clad plates ........................................................................................ 15
1.3.1 Roll cladding .......................................................................................... 15
1.3.2 Explosion cladding ................................................................................. 15
1.4 Properties of clad plates........................................................................................... 16

2. Welding of clad plates ........................................................................................................... 17

2.1 Welding processes .................................................................................................. 17
2.2 Filler metals ............................................................................................................ 18
2.3 Joint design............................................................................................................. 21
2.3.1 Basic criteria ........................................................................................... 21
Table 2.18 - 11 ............................................................................................... 23
2.3.2 Butt welds ................................................................................................ 24
2.3.3 Fillet welds .............................................................................................. 24
2.4 Performance of welding .......................................................................................... 24
2.4.1 Purity ...................................................................................................... 25
2.4.2 Preheat .................................................................................................... 25
2.5 Postweld heat treatment (PWHT) ............................................................................ 26
2.6 Subsequent treatment of the welded seams.............................................................. 26

3. Wear-resistant clad steel ....................................................................................................... 26

4. Coated steels ....................................................................................................................... 27
4.1 Welding of steel with a metallic coating (general) ................................................. 28
4.2 Welding Zn-coated steel ("galvanized" steel) ......................................................... 28
4.3 Welding of steel coated with primers ...................................................................... 29

5. Hard facing ........................................................................................................................... 30

5.1 General considerations ............................................................................................ 30
5.2 Performance of surfacing......................................................................................... 31
5.3 Hardfacing processes .............................................................................................. 33
5.4 Hard facing alloys ................................................................................................... 34
5.5 Machining of the deposits........................................................................................ 36
5.6 Heat treatment ......................................................................................................... 36
5.7 Examples of hard surfaced parts .............................................................................. 38
5.7.1 Material which can be treated mechanically ............................................ 38
5.7.2 Material which will protect against abrasion caused by rolling
friction and impact ...................................................................................39
5.7.3 Material which will protect against abrasion through sliding
friction ..................................................................................................... 39

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 PROTECTIVE LAYERS

1. Corrosion resistant clad steel

1.1 Examples of clad plates
thickness (mm) composition
limits mainly
cladding 1.5 - 10 2-4 see table 1.1-1
base metal 6 - 80 8 - 20

Table 1: Examples of cladding materials for clad plates

DIN AST typical chemical composition (%)
Werkstoff Nr. M C max Cr Ni Mo Cu others
1.4000 type
410 S .08 13 - - - -
1.4306 304 L .03 19 11
1.4541 321 .08 18 10
1.4404 316 L .03 17 12 2
Alloy
1.4539 904 L .02 20 25 4.5 1.5 NO.1
2.4858 825 .025 21 42 3 2 Ti 0.9
2.4856 625 .025 21 63 9 Nb 3.5
2.4610 C4 .01 16 67 16 Ti 0.6
2.4617 B2 .01 71 28
2.4360 400 .15 63 31
2.4068 Ni201 .02 99
2.0070 Cu 100
2.0872 CuNi 90-10 .05 10 90
3.7025 Ti-Gr. 2 .08 Ti 100

Base metals are carbon steels like ASTM A515 Gr. 60 or A516 Gr. 70 or steels with
0.5Mo or 1 1/4Cr - 1/2 Mo.

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The optimal heat treatment for base and cladding metal is very different (Fig. 1 ). Austenitic Cr-Ni-steels,
but especially Cr-Mo and Mo containing Ni-alloys need after hot rolling a solution heat treatment at 1000
to 1150°C followed by a water quench to achieve optimal corrosion resistance. These high temperatures
cause coarse grain and the water quench a hardening of usual (normalized) steel. The results are bad
impact strength and high tensile strength of the base metal. Grain growth may be avoided by microalloying
with Nb or Ti and hardening by lower C, but analysis may be then outside of a standard.
On the other hand annealing or PWHT necessary for the base metal may cause sensitation of the
cladding metal.

Fig.1 Heat treatments for austenitic and plain carbon steels

1.2 Advantages of clad plates over high-alloyed solid plates

 reduced wall thickness caused by the higher yield strength of the low-alloyed base metal compared
with the high-alloyed solid plate;
 improved heat conductivity by the low-alloyed base metal and the reduced wall
thickness; * savings in weight;
 savings in material costs. These are the higher, the higher the price of the cladding material and the
thicker the plate;
* the volume of welding is smaller,
* roll clad plates can be supplied with larger plate formats than is possible with solid plates.

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1.3 Production of clad plates

Clad plates are only produced on order and are not available fromstock.
1.3.1 Roll cladding
Roll cladding is a solid-state welding process. Clean contact surfaces of base and cladding metal are
necessary to obtain a good bond. This is achieved by grinding these surfaces and protect them against
oxidation during heating up to hot rolling temperature by one of the following methods:
* covering with a thin layer of Ni by electrolysis (Process of Luckens (USA));
* explosion cladding before hot rolling. In this case hot rolling is no cladding process but used only as
a means to achieve thinner plates of bigger size;
* welding of a package and evacuating (Process of VOEST-ALPINE (Austria): Fig. 2)

Fig. 2 Roll cladding

1.3.2 Explosion cladding

The explosion welding process is described in Chapter B 1.15 ("Other welding processes").

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1.4 Properties of clad plates
The properties of clad plates are specified e.g. in the standards ASTM A 263, A 264, A 265 and B 432
or in the German standard "AD-Merkblatt W8".
First a clad plate is tested by UT in respect to unbonded areas. Single unbonded areas are permitted up to
50 cm2 or a diameter of 75 mm. The total of all unbonded areas is usually limited by 5 % of the plate
area.

Fig.3 Fig. 4

Mechanical tests include tensile and impact tests (Fig. 3). The bond strength is proven by bending tests
but determined by a shear test. The AD-Merkblatt W8 specifies a minimum shear strength of 140
N/mm2 in the shear test. With the VOEST-ALPINE roll cladding process actual shear strength is
substantially higher (Fig. 4). The shear strength is important if parts are to be welded perpendicular to
the cladding. A shear strength according to Fig. 4 is sufficient that even highly over-dimensioned fillet
welds like the one shown in Fig. 5 do not result in a detachment of the cladding.
Sometimes a permissible unbonded area will be visible by FT in a butt joint preparation. In this case a first
run by GTAW is recommended to weld the unbonded length of the joint before other welding processes are
applied.

About 1% of clad plates contain not permissible defects. In this case standards admit a repair of the
defects by welding by the manufacturer of the plates if qualified welders and a qualified welding
procedure are applied. It is wise to specify in the order that the manufacturer should inform the
customer ahead of a repair welding (to avoid repairs which are a technical nonsense) and that a sketch
with the location of the repairs should be delivered together with the plate.

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Fig. 5 Cross section of fillet weld on clad plate Fig. 6 Crack at the border of explosion
clad plate

The thickness of the total plate and the thickness of the cladding are measured by visual, magnetic-
inductive or ultrasonic methods. The thickness of the cladding at the borders of the plate is higher than in
the center of the plate. Joint design must be adjusted to the real thickness of the cladding at the joint.

Ductility is low at the borders of explosion clad plates. This may be the cause of cracks during
welding (Fig. 6 ) if not enough material has been cut away during production of the plates.
Corrosion tests are seldom part of a specification for clad plates. It is assumed that the manufacturer
chooses a proper production process and tests the corrosion resistance of his own accord.

2. Welding of clad plates

2.1 Welding processes

For the base metal standard processes such as manual arc welding (SMAW), MIG welding (GMAW) with
solid or flux cored wire (FCAW), submerged arc welding (SAW) and TIG welding (GTAW) are used.

For the cladding metal welding processes are selected that ensure a low level of dilution by the base
metal (Detailed information on weld cladding processes is given in Chapter B 1.15. Here only general
information is provided):

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 * Manual arc welding (SMAW) with thin electrodes, low welding current and good overlapping of
the welded beads.

* TIG welding (GTAW) is particularly suited to high-alloy steels and non-ferrous metals, especially
where smooth weld surfaces are required. Mechanized TIG pulse welding with cold or hot wire offers
excellent welding performance and requires limited finishing.

* MIG (GMAW) pulse welding furnishes high deposition rates. However, the dilution by the base metal
is somewhat greater than in 110 welding. Important for a low level of dilution is the correct selection
of pulse duration and frequency and a long electrode stick-out. The weld surface is rougher than is the
case with TIG, although some flux cored wires bring an improvement in this regard. Flux cored wires
for the final layers must have a sheath (tube) in a similar metal to that of the cladding. This is only
true for a few of the standard types of weld metal currently available.

* Electroslag (ESW) or submerged arc (SAW) cladding with mostly 15, 20 or 30 mm wide strips. In this
case, the back cladding can often be achieved with a single layer. Joint design, and the correct choice
of strip analysis and welding parameters are of decisive importance.

2.2 Filler metals

For the welding of the base metals, the same filler metals are used as for plates without cladding.
For the cladding materials examples of recommended filler metals are listed in the Tables 2 and 3.
Recommendations are based on the following criteria:

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Table 2
Example of filler metals for the
welding of corrosion and heat
resistant cladding materials
According to DIN 8556, DIN 1736,
AWS A 5.3, A 5.9 and A 5.14

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 Table. 3

X2 CrNiMoCu X2 CrNiMoCu 20 25
1.4505 20 25

X2 CrNiMoCu X2 CrNiMoCu 20 UP-NiCr21Mo9Nb ERNiCrMo-3

1.4539 Alloy 904L 20 25 5)
5
25 )

1.4563 Alloy 28
SG-NiCr21Mo9Nb ERNiCrMo-3 SG-NiCr21Mo9Nb ERNiCrMo-3
UP-NiMoT6CrI6Ti ERNiCrMo-7
1.4529

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 If possible, the first layer should be welded with an over-alloyed filler metal in order to get in the
mixture with the base metal a composition similar to the cladding.

 For 13% Cr-steel cladding, not only the buffer layer but also the following layers are welded with an
over-alloyed type E309 austenitic electrode. Using the normal E308 types would result in the danger
of the formation of martensite, should an increased mixture with the 13% Cr-steel occur. The E309L
Type electrode is also recommended for the buffer layer when the final layer is composed of 13% Cr
weld metal, as cracks can develop if 17% Cr electrodes are utilized as a buffer electrode.

* Low carbon 18Cr8Ni- and 18Cr IONi2Mo-steels are not prone to intercrystalline corrosion due to a
postweld heat treatment (PWHT) of 2 hours at 500 - 700°C. The same PWHT would cause
susceptibility to intergranular corrosion in a low carbon weld metal. Therefore, (in the case of a
PWHT) an Nb stabilized weld metal with a low carbon content is advisable.

* For austenitic steels and Ni alloys with more than 2.5% Mo (where possible), the recommended filler
metals for the final layers should be over-alloyed to a factor of 1.2 with regard to Mo. This must occur
when this material is to be utilized where there is a danger of pitting corrosion. In this case the equation
% Cr + 3.3 % Mo is decisive. In the weld metal Mo is segregated to a greater extent than in the
cladding metal, which results in Mo impoverished zones with only 80% of the average Mo content.

 When welding Cu, CuNi 90/10 and CuNi 70/30 directly onto steel, there is a tendency for cracking.
Therefore, in the table 3 a buffer layer with monel is advised.

2.3 Joint design

2.3.1 Basic criteria

* Joint design and performance of welding must be executed so that the weld metal for the base metal
does not touch the cladding at any time. This is intended to prevent the creation of a weld metal which
is brittle (martensitic) or prone to hot cracking. The actual thickness of the cladding must be taken into
consideration during the preparation of the weld edges.

 The full alloy content (or a limitation to a maximum of 5% Fe in the case of Ni or monel) is often only
attained in the third layer. Therefore, on the cladding side a weld reinforcement of 2 - 3 mm is
permissible, in order to create enough space for the third layer (Fig. 7). If the weld reinforcement is
restricted, the first and second layers must be heavily ground prior to further welding.

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* Wherever possible, the back gouging of the base metal weld, should only take place on the base metal
side, with the aim of avoiding soiling of the cladding (see weld forms 2) and 3) in table 4.

Fig. 7 Reinforcement of butt welded clad plate Fig. 8 Joint design for Ti clad plates

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 Table. 4

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2.3.2Butt welds

The joint designs in table 4 are valid for clad plates in which the base and cladding metals can be fusion
welded without the formation of brittle intermetallic phases.
In the case of titanium fusion welding of the base and cladding metals is impossible due to the creation of
such phases. Therefore, for the butt welding of titanium clad plates a special joint design is used (see table.
4).

Fig. 9 SA fillet weld with about 10 % dilution

2.3.3 Fillet welds

The ultrasonic testing standards for clad plates permit unbonded areas of a certain size. Therefore, during the
welding of fillet welds onto the cladding, it is essential that the bond of the cladding in the area of the weld is
checked by the purchaser ultrasonically both before and after welding. Cutting back the cladding with
subsequent weld cladding, as a preparation for the fillet weld, is only necessary when ultrasonic testing has
discovered defects in the bond or if the shear strength of the plate is lower than about 250 N / mm2.
If the fillet welds are welded with a minimum of around 10% overalloyed filler metal, the welding seam may
melt through the cladding to an extent that the dilution by the base metal amounts to 10 % (Fig. 9 ).

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2.4 Performance of welding
2.4.1 Purity

During the welding of the cladding metal, the same purity demands are to be observed as in the case of
similar solid metals. In other words, stainless steel pick hammers, brushes, etc. must be used. With Ni and
Ni-alloys for example, the avoidance of all forms of sulphur contamination is the primary rule. Therefore,
grinding discs with sulphur-free binding material are essential.

2.4.2 Preheat

* Welding of the base metal:

The preheat temperatures must be chosen according to the rules given in Chapter B 2.8.
* Welding of the buffer layer:
Most of the buffer layers are welded with austenitic weld metal which gives off only little hydrogen to
the base metal. In this case, preheating can be lower than quoted in Chapter B 2.8 for the base metal
- for SMAW, around 50°C lower
- for GMAW (M.I.G.), GTAW (T.I.G.), ES (electroslag) or SA strip cladding up to 100°C lower.

* Welding of the cladding: see table 5.

Filler Preheat Interpass Heat

Cladding
metal temperature temperature input
13 % Cr steels austenitic none
min. ° C 200
max. ° C low
type 13 % Cr 150 250 "
aust.CrNi steels similar none 150 low to medium
Ni and
similar none (100) 150 low
Ni
alloys similar 3 mm: 100
Cu 4 mm: 200 400 medium
5 mm:
CuNi and 300 ≥ 6mm: Low to
similar 180
NiCu alloys 300
none medium
Ti similar —400
none 150 low

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2.5 Postweld heat treatment (PWHT)

PWHT is generally only required for the base metal. Recommendations are given in the standards for the
base metals. The characteristics of the cladding and the related welding material generally deteriorate
during PWHT, as a consequence of the formation of carbides and intermetallic phases. PWHT is
therefore to be avoided (see also section 2.2).

2.6 Subsequent treatment of the welded seams

According to the type of cladding and the corrosive medium, a flattening of the welded seam to prevent
deposits (crevice corrosion) or pickling to remove heat tints beneath the weld or similar measures may
be necessary.

3. Wear-resistant clad steel

Wear-resistant clad steel plates consist of a hardenable layer on a tough base metal. The thickness of the
cladding is 20 to 50% of the total thickness of the plate, which is 4 to 60 mm.
Examples for cladding materials are given in table 6. Base metal is a low carbon steel which remains
tough during hardening.

Table 6: Examples for wear-resistant cladding materials (steels and iron alloys)
main components hardness hardening quenchin temper application
(%)
C Mn Cr Mo (HRC) temperature (°C) g in (°C)
0.75 0.7 0.25 65 800 water <180 wear
0.85 0.3 1.75 0.27 66 835 oil, water <300 wear
0.46 <1 13.5 56 975 oil, water <300 wear
+ corrosion
2.10 0.3 11.5 65 935 oil, water <500 hot wear

Application: Such wear-resistant clad plates are used for:

* ore and coal mining;
* mineral mining and processing;
* protective structures.

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The plates are delivered in the annealed condition. In this condition processing of the plates is possible:

* cutting, e.g. by saw or shear cut or by plasma cut (preheating between 200°C and tempering temperature);
* forming: - cold for thin plates, wear layer in the pressure zone
- at 200 - 400°C for low tensile loads on the wear layer
- at max. 700°C for large scale forming;
* welding in the annealed state, the base metal is welded first. If required the cladding can be welded with
amatching weld metal. But this is very difficult due to the high carbon content of the wear resistant
layer which causes cold and hot cracks.

Fig. 10
If the plate is already hardenened only the base metal can be welded (Figure). The weld should not
anneal the wear resistant layer. The gap between the plates will be closed by shrinking.

4. Coated steels

There are the following types of coatings:

* metallic coatings like Zn, Cu, Cr, Ni
* inorganic coatings like enamel, phosphates
* organic coatings like lac or primer.

Metallic coatings are produced by:

* hot dip (immersion in fused metal)
* electrolytic coating
* vapor
* spraying
* cladding

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4.1 Welding of steel with a metallic coating (general)

When welding steel with a metallic coating the following difficulties could arise:
* hard weld metal due to alloying by the coating;
* cracks in the weld metal (e.g. by Zn);
* cracks in the base metal (e.g. by Cu);
* porosity (e.g. by Zn).

Electrolytic coatings e.g. with Cr or Ni are usually very thin and cause only a slight increase of the weld
metal strength.
Coatings with Cu or brass may cause cracks in the base metal by diffusion of Cu along to the grain
boundaries.
4.2 Welding Zn-coated steel ("galvanized" steel)

Table 7: Examples of Zn-coated steels

plate thickness application coating process coating thickness coated surfaces
(mm) µ
electrolysis 5 - 10 1 or 2
1 e.g. car electrolysis (Zn + 11% Ni) 2 - 6 1 or 2
hot dip 7 - 14 1 or 2
2 - 20 e.g. bridge hot dip 60
6 - 80 2

Resistance spot welding of Zn-coated steels: parameters are restricted. Lifetime of electrodes is shorter,
depending on type and thickness of coating (see Chapter B 1.12).

Arc welding of Zn-coated steel

Main problem is porosity by Zn vapor (boiling point 906°C), more spatter and fumes. Rutil electrodes
cause less porosity compared to basic electrodes or GMAW or SAW. With GMAW weaving in the
welding direction and back, with SAW lower welding speed may reduce porosity.

Butt welds give less problems than fillet welds.

Weld metal may contain up to 0.08% Zn without loss in mechanical properties.

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Fillet welds on plates which are Zn-coated on all surfaces may give cracks in the weld metal (by Zn)
with SMAW > 10 mm thickness,
with GMAW > 5 mm thickness.
Three conditions are necessary for these cracks:
* three axial strain
* liquid Zn (can be avoided by a gap of more than 1 mm which allows the Zn to vaporize)
* diffusion along to the grain boundaries (which is slower with a low Si, low Mn weld metal).
With arc welding Zn is oxidized (white fume). Therefore the weld and the area beneath the weld must be
carefully cleaned. The corrosion resistance must be restored by painting with a Zn powder lac or spraying
with Zn.
In the car industry the GMA welding of Zn-coated sheet by overlap welds is done with the low alloy wire SG
1 which has the advantage of a less fluid weld metal.
Laser beam welding of Zn coated sheet in the automotive industry gives a welded seam which is
corrosion resistant due to the fact that Zn is vaporized only in a very narrow area.

4.3 Welding of steel coated with primers

Steel is coated with primers to avoid rust during manufacture. After sand-blasting (roughness 20 - 100 µ)
a coating of 5 to 25 (preferably 10 - 15) it is sprayed on all surfaces. The coating may be removed before
welding. If not, porosity of the weld depends first on the composition of the primer and secondly on the
roughness of the plate and the thickness of the coating.
Similar to the welding of Zn-coated steel rutil electrodes give the lowest porosity and GMAW a higher
one (Fig. 11). With SAW additional to porosity the slag detachability is worse. In all cases porosity can
be reduced by a gap in the fillet weld.
Welding of primer coated steel causes unpleasant gases and vapors and should be done with good ventilation.

Fig. 11

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5. Hard facing
This item deals only with hard surfacing by welding. Surfacing by spraying is discussed in Chapter B
1.15 (Surfacing).

5.1 General considerations

* Scopes: - restoration of the shape and size
- protection of the surface against wear or corrosion
* Type of surface attack: - pressure
- type of wear
- temperature
- medium

* The type of surface attack and the base metal are decisive for the - choice of the welding process
- choice of the filler metal

* Further considerations:
- effect on the base metal
-construction of the welded part
- thickness of protective layer
- strength
- access to the welded surface
- who will do the job
- economics

* Rules: - the properties of the suface layer are affected by the dilution
- in the case of high pressure or impact the surface layer
o must be thicker
o must be tough
o should not contain big steps in hardness
- very hard layers are prone to cracks
- the fusion area between base metal and the surfacing must withstand the differences in hardness
during service
- partial surfacing must consider the effect on the neighborhood

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5.2 Performance of surfacing
* Base metal:
- type of steel?
- composition?
- mechanical properties?
- condition of heat treatment?
- cracks?
* Choice of filler metal
* Edge preparation
- remove scale, rust, dirt, grease
- remove damaged (cracked, fatigued, corroded) material
- prepare edges without sharp corners (Fig. 2.18-18)

Fig. 12 Edge preparation for hardfacing

* Minimizing distortion
- firm clamping of part
- some deformation (bending) prior to welding to counteract distortion (Fig. 13)
Before After Deformation prior to welding to counteract distortion

wrong

Right
Fig . 13 Bending prior to hard facing

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* for building up on corners and edges use suitable shaped pieces e.g. of copper plate to back up the
weld pool leaving a 1 - 2 mm gap for slag flow
* Preheat:
- preheat for low alloy steel (Table 8 ) is mostly sufficient for the hard surfacing weld metal. The
higher preheat temperature in Table 8 is valid for thicker parts or lower heat input.

Preheating temperatures for building up on steel

Table 8
Main exception: Co alloys
- when hard facing steels which must not be preheated (mild steels preheat must be chosen according
to the weld metal)
- preheating should be done slowly and uniformly (optimal: furnace: propane burner)

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* Performance of welding in the case of tools
- choose small diameter of electrode
- start welding at the deeper position
- weld with low heat input
- choose correct sequence of welding operation e.g. step-back welding (length of the bead 2 - 3 cm)
- omit deep end crater
- hammering each bead will relieve stresses
- do not interrupt welding
- provide for slow cooling (isolation, furnace)

5.3 Hardfacing processes

The general rules how to achieve a small dilution and most of the cladding processes described in
Chapter 1.13 are also used for hard surfacing. The properties of these processes are:

* gas (oxyacetylene) welding: little dilution; reduced risk of crack formation due to high heat input and
wider heat affected zone. Easy control of welding operation and of shape of the deposit.
Only Ni-B-Si alloys are welded with a neutral flame. All other alloys (containing much carbon) require
an excess of acetylene.

* GTAW (TIG): dilution very variable;

low heat input possible (low distortion), good control of shape of deposit, low deposition rate. A
special application is the welding of Co-alloys with Cr and W.

* SMAW (manual metal arc): low heat input and small HAZ, all welding positions
possible universal application

* GMAW (MIG): higher deposition rate (cold wire addition) for larger areas.

* Flux cored wires: normal application without shielding gas (but also used with shielding gas or for
SA welding): High deposition rates (4 - 8 kg/h); for large areas mechanized welding.
Flux cored wires for hard facing may contain high percentages of C, Cr, W, Nb etc., that is alloys
which cannot be produced in the form of bare wires.

* SA welding with wire: high dilution, high deposition rate. For large areas
* SA welding with strip: low dilution, particularly suitable for large area

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* Plasma powder surfacing: welding of granular filler metals; therefore a variety of surfacing materials
on the basis of Fe, or Ni or Co weldable. Weaving is necessary due to the hot plasma to reduce dilution.
The plasma powder surfacing equipment is expensive and therefore only applied for mass-production,
e.g. contact faces of valves.
Table 9 : dilution of hard facing processes (the values apply for bigger areas (not for single beads))
Process Dilution
Gas (Oxyacetylene) welding 1(%) -5
SMA (Manual metal arc) welding: low current 10 - 15
high current 15 - 30
Flux-cored wire 20 - 40
Plasma powder surfacing 5 -8

5.4 Hard facing alloys

There is a great variety of surfacing alloys. Most of them are classified in the German Standard DIN 8555 in
17 groups(Table 10 ). These groups can be divided into 4 main groups:
A) Martensitic Fe-alloys: groups 1, 2, 3, 4, 5, 6
B) Austenitic Fe-alloys:
group 7, 8: against impact (work hardening)
group 9: against corrosion + wear

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C) Carbide containing Fe-alloys: group 10
D) Non-ferrous alloys
group 20: Co-alloys
group 21: (W-)carbides
groups 22 + 23: Ni-alloys
groups 30, 31, 32: Cu-alloys

Table 10 contains the most important properties and applications of the surfacing materials mentioned
in DIN 8555. Additional remarks are necessary for the following groups:

* Group 7: austenitic Mn-steels

These steels have only a hardness of 200 HB. But by work hardening the surface may achieve a hardness of
up to 600 HB whereas the core retains its toughness. As abrasion progresses the work hardened surface
layer keeps renewing intself. Austenitic manganese steels are therefore ideally suited for components in
bard crushing equipments which have to withstand extreme impact and shock loads. Without a possibility
for work hardening austenitic manganese steels do not offer any better wear resistance than an unalloyed
0.45% C-steel.

Austenitic Mn-steels embrittle by carbide precipitation between 400 and 600° C, which may induce
crack formation. Therefore they should be welded as cold as possible:
- without preheat
- with low heat input (string beads with low current)
- spraying each bead with water

Austenitic Mn-steels are more liable to distortion. Counter

measures are:
- firm clamping
- hammering each bead to relieve stresses
- welding of staggering beads (reduces also heat input)

* group10: Cr-cast iron

Due to high carbon content of 3 - 6 % C and carbide forming elements (Cr, W, Mo, Nb, Ti) such
surfacing materials have a very high resistance against abrasive wear up to higher temperatures (500° C)
and are also corrosion resistant. They are very sensitive for cracking, already after welding or by impact
But abrasion resistance is given also in cracked layers. Only thin (single) layers do not crack.

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* Group 20: Co-Cr-W alloys
These alloys have a tough, corrosion and heat resistant austenitic Co matrix with very hard, wear
resistant carbides. There is only a slight drop in hardness up to 700° C. Welding should therefore be
done with a preheat of 300 to 700° C (depending on the content of C and hardness) and slow cooling to
avoid cracks.

5.5 Machining of the deposits

Machinability of the deposits is governed by chemical composition and hardness. Machining may be
difficult and expensive. therefore a surfacing process (or skill) which provides for a smooth surface may
be a big economic advantage.
Turning is possible up to 35 HRC with HSS tools
up to 50 HRC with tungsten carbide tools and
up to 60 HRC with special tools.
Very often buildups are ground. The circumferential speed of the grinding wheel should not be too high
(15 -30 m/s).

5.6 Heat treatment

The hardness of Co or Ni hard facing alloys cannot be changed by a heat treatment. Deposits of
martensitic steels may gain some hardness, a temper around 500° C which transforms residual austenite
into martensite. Such deposits may also be better machinable after annealing. After machining the
hardness may be restored by a quench and temper heat treatment.

Martensitic weld metal is tempered by following welding. Therefore it is difficult to obtain a

homogeneous hardness. Differences in hardness in the deposit may be as high as ± 5 HRC.

Table 10 : Metal groups for surfacing according to DIN 8555

group type of alloy microstructure hardness application
1 Fe with max 0.4 % C and max martensite 200 - 400 rails, track
rollers,agricultural machine
5 % (Cr + Mn + Mo + Ni) e.g. HB
components
0.2 C; 1 Si; 1 Mn; 2 Cr
2 Fe with > 0.4 % C and max 5 martensite 52 - 60 HRC rock crushing equipment,
% (Cr + Mn + Mo + Ni) earth moving equipment,
worm conveyors, mixer
paddels

M1.2.21 Page 25 of 29
M1.2.21 Page 26 of 29
 20 Co + Cr + W (Ni, Mo) and C carbides in 38 - 60 HRC contact faces of valves and
"Stellite" austenitic Co- fittings in gas, steam and
abrasion and corrosion Cr matrix acid
resistant up to high preheat: 300 - 700° C!
temperatures e.g. 1.2 C; 27 Cr;
21 Carbide base
4 W; 64 Co W carbide in Fe 60 - 75 HRC rock drills, drawing dies, sand
(sintered or cast; not fused (Ni) matrix processing plant,
during welding) woodworking tools,
e.g. 80 WC, 20 Fe ventilators
22 Ni-Cr-B carbides of 40 - 60 HRC rolls
hard at high temperatures Cr + B in high preheat (up to 600°
filler metals: powder or sintered Ni matrix C) slow cooling!
rods
23 Ni + Mo (± Cr) 220 - 400 hot work tools,
(Hastalloy) HB sealing faces of slide and other
high resistance against corrosion valves
30 Cu + Sn sliding
31 Cu + Al corrosion resistant
32 Cu + Ni corrosion resistant (chlorides)

5.7 Examples of hard surfaced parts

5.7.1 Material which can be treated mechanically

For workpieces and construction parts which have to be treated mechanically after the building-up
welding. A hardness value of 400 HB should not be exceeded in this method.
Used for rails, rolls and chain links.

chain link
crane wheel Tread roller
Fig. 14

M1.2.21 Page 27 of 29
5.7.2 Material which will protect against abrasion caused by rolling friction and impact

For all parts which must withstand abrasion caused by rolling friction together with impacts, and where
a machining treatment is not necessary. The material to be welded need only be treated by grinding.
Used for rabbet edges, crusher jaw plates, excavator buckets.

rabbet edge crusher jaw plate

excavator bucket
Fig. 15

5.7.3 Material which will protect against abrasion through sliding friction
These alloys contain up to 50 % Cr carbides which are embedded in the base. By adding tungsten and
niobium, hardness can be improved very considerably due to 65 HRC, due to increased carbide
formation. This material is exceptionally well suited to protect against grinding abrasion, but it is
sensitive to impact and percussion. Used in processing ore, rock and ballast.

excavator tooth scraping edge Conveyor worm

Fig. 16

M1.2.21 Page 28 of 29
 5.7.4 Material which is strain hardening

By this is meant austenitic manganese steel with a C content of 1 to 1.5 % and a Mn content between 12 and 18
O/o, also called hard manganese steel. This material, which is by nature, soft and ductile, hardens considerably at
the surface when strain by pressure or impact is exerted on it. This ensures high resistance to abrasion together
with high ductility. This material is employed in cases where a high strain through pressure and impact is
combined with abrasion, for instance in crusher jaws, crushing heads, beaters.

crushing head grinding roll crusher jaw plate

Fig. 17

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