Getting the best welding results

Clean the weld area to remove moisture, oil, corrosion or any impurities prior to welding. In addition
to good welding hygiene, make sure you consider the following aspects:
 Choice of welding consumables
 Preheat and interpass temperatures
 Heat input
 Weld sequence and size of root gap in the joint

Welding consumables
Strength of unalloyed and low-alloyed welding consumables
Unalloyed and low-alloyed consumables with a maximum tensile strength of 500 MPa (72
ksi) are generally recommended for Hardox. Consumables of higher strength (Re max.
900 MPa/130 ksi) may be used for Hardox 400 and 450 in the thickness range 0.7 – 6.0 mm
(0.028” – 0.236”). Low-alloyed consumables result in higher hardness of the weld metal
which can reduce the wear rate of the weld metal. If the wear properties of the weld metal
are essential, the top cap of the joint could be welded with consumables used for
hardfacing

Shielding gas
Shielding gases for Hardox wear plate are generally the same as usually selected for unalloyed and
low-alloyed steels.

Figure 1: Shielding gas mixtures and their effect on the welding operation

Ar/CO2
- Stable arc
- Reduced amount of spatter
- Reduced amount of slag
- Increased productivity
CO2
- Good side wall penetration
- Reduce amount of porposity
- Less risk for lack or fusion
Examples of shielding gas mixtures and recommendations

Welding method Arc type Position Shielding gas

MAG/ GMAW, solid wire Short Arc All positions 18 – 25% CO2 in
Ar
MAG/ MCAW, metal Short Arc All positions 18 – 25% CO2 in
cored wire Ar
MAG/ GMAW, solid wire Spray Arc Horizontal 15 – 20% CO2 in
Ar
MAG/ GMAW, FCAW Spray Arc All positions 15 – 20% CO2 in
Ar
MAG/GMAW, MCAW Spray Arc Horizontal 15 – 20% CO2 in
Ar
Robotic and automated Spray Arc Horizontal 8 – 18 % CO2 in
MAG/GMAW
Ar
TIG/ GTAW All positions 100% Ar

Note: Gas mixtures including three components, i.e. O2, CO2, in Ar are sometimes used in
order to optimize the weld properties.

In all welding methods based on shielding gas, the flow of shielding gas depends on the
welding situation. As a general guideline, the shielding gas flow in l/min should be set to
the same value as the inside diameter of the gas nozzle measured in mm.

Heat input
Heat input (Q) is the amount of energy applied to the base material per length unit. Heat
input is calculated according to the formula below:

𝐤×𝐔×𝐥×𝟔𝟎
Q= Kj/mm
𝐯×𝟏𝟎𝟎𝟎
Q = Heat input kJ/mm (kJ/inch)

k = Arc efficiency (dimensionless) U = Voltage

I = Current
Various welding processes have different thermal efficiency

Weld method Thermal efficiency (k)

MAG/ GMAW 0.8
MMA/ SMAW 0.8
SAW 1.0
TIG/ GTAW 0.6

Excessive heat input increases the width of the heat affected zone (HAZ), which in turn
impairs the mechanical properties as well as the wear resistance of the HAZ. Welding with
low heat input provides benefits like these:

 Increased wear resistance of the HAZ

 Decreased distortion (single-pass welded joints)
 Increased toughness of the joint
 Increased strength of the joint

Cooling time t8/5

The cooling time (t8/5) is the time that it takes for the weld to cool from 800° – 500°C
(1472° – 932°F), and it represents the key element of the final microstructure in the weld.

Recommended cooling times are often provided for structural steels in order to
optimizethe weld process for a certain requirement, such as meeting the minimum impact
toughness.

Preheat and interpass temperatures

It is essential to follow the recommended minimum preheat temperature as well as the

procedure for obtaining and measuring the temperature in and around the joint in order to
avoid hydrogen cracking.

Influence of alloying elements on the selections of preheat and interpass temperatures

A unique combination of alloying elements optimizes the mechanical properties of Hardox.

This combination governs preheat and interpass temperatures of Hardox steel during
welding, and can be used to calculate the carbon equivalent. Carbon equivalent is usually
expressed as CEV or CET according to the formulas below.
The alloying elements are specified in the mill certificate of the plate and are stated in
weight percentages in these two formulas. A higher carbon equivalent usually requires a
higher preheat and interpass temperature.

Hard facing

If the weld joint is located in an area with the expectation of high wear, you can employ
hardfacing with special consumables to increase the wear resistance of the weld metal.
Both the instructions for joining and hardfacing for Hardox should be followed. Some
consumables for hardfacing require a very high preheat temperature that may exceed the
maximum recommended interpass temperature for Hardox steel. It is worth noting that
using a preheat temperature above the maximum recommended interpass temperature for
Hardox steel may reduce the hardness of the base plate and result in deterioration of wear
resistance of the preheated area.Minimum and maximum preheat temperatures are the
same as for conventional types of welding;

Figure 7: Definition of single plate thickness

Figure 8: Example of welding sequence using consumables for buffer layer and hard facing
It is beneficial to weld a buffer layer with extra high toughness between the ordinary
welded joint or plate and the hard facing. The choice of consumables for the

buffer layer should follow the welding recommen- dations for Hardox wear plate. Stainless
steel consumables in accor- dance with AWS 307 and AWS 309 should preferably be used
for the buffer layer

Recommendations for minimizing distortion

The amount of distortion during and after welding is related to the base plate thickness and
welding procedure. Distortion becomes more obvious in thinner gauges, while heavy defor-
mation or even burn-through can cause problems and can compromise the whole
structure.

 Minimize the amount of distortion during welding by following these

recommendations:
 Weld with a heat input as low as possible (single pass welded joints).
 Minimize the cross sectional area; see Figure 9.
 Prebend, clamp or angle the parts before welding in order to compensate for the
deformation; see Figure 10.
 Avoid an irregular root opening.
 Use symmetrical welds; see Figure 9.
 Minimize reinforcements and optimize the throat thickness of the fillet welds.
 Weld from rigid areas to loose ends.
 Decrease spacing between the tack welds.
 Use a back-step welding technique

:Cross section of the weld and how it influences the angle deviation
Presetting of a fillet joint and a single-V butt joint.

Use a symmetrical weld sequence

Example of back step welding technique

Generalities - Hard Load Applications:
With the help of welding, the parts exposed to different types of wear are protected in
order to obtain either resistance to a certain type of wear or a certain specific property.

Although welding load is used to recondition worn parts to increase service life, it is often
useful to use this technology to make new parts. The piece can thus be made of cheaper
material and the properties required for the active surfaces are achieved by welding with a
material whose properties fit the respective non-essential elements.

Welding materials can be applied practically by any welding process.

Increased hardness does not necessarily mean better wear resistance or longer service life.
A series of alloys can have about the same hardness and wear resistance to vary
significantly.

Experience has shown that the choice of the most suitable material for welding loading
should know the conditions in which the piece will work.

In order to be able to choose a material suitable for a concrete use, the following
information is required:

 which are the factors of wear

 which is the basic material
 which welding process is preferred
 which is the appearance of the surface after loading

Wear factors:

There are many wear factors that act independently or in different combinations. On this
basis you must carefully identify and carefully select a suitable material with the right
properties to ensure the efficiency and safety of the repair.

An alloy for loading should be chosen as a compromise between the various existing wear
factors.
For example, when it is established that the first wear factor is the abrasion and the
secondary factor is the moderate impact, the welding load material chosen must have
abrasion wear resistance but at the same time a good level of impact resistance.

By simplifying the wear system, they can be classified into separate categories with very
different characteristics.

Metal - metal wear, rubbing or slipping wear

It is the wear of metal parts that roll or slide over one another, such as, for example, a shaft
and the surface of a bearing, the chains of the roller, the chain wheels, the rollers of the
mills, etc.

For this type of wear fit martensitic metallic materials for welding loads. Manganese
austenitic alloys or cobalt alloys can also be used.

In general, contact between the surfaces of the same hard materials results in excessive
wear. Therefore, for surfaces of parts that work in mutual contact, eg shaft and bush, it is
necessary to choose materials with different hardness.

Impact:
The surface of the material exposed to hits and / or high pressures deforms or breaks and
breaks. Impact wear also produces crushing and grinding along with fine particle
abrasions. Such conditions require the existence of strong, wear-resistant surfaces.

Load with manganese austenitic steel that is ecruising, withstands the impact of wear. Hard
surfaces are formed and the material underneath them is tenacious. Martensitic alloy
deposits also have good impact resistance though they are not as good as manganese
austenitic ones. Typical components are the different parts of the crushers, the crushing
hammers, the tips of the tracks of the railway tracks, etc.

Abrasion with fine mineral particles.

This type of wear is caused by fine particles that slip or flow on the metal surface at
different speeds and at different pressures and thus erodes the surface of the material, as if
it were small cutting tools. The more these particles are stronger and the more sharp they
are, the more abrasive they are.
We encounter typical examples of abrasive wear for tearing, drilling, mineral transport,
agricultural machinery, etc.

Due to the absence of impact wear, carbon steel and chromium alloys, which are relatively
fragile, such as carbide-containing alloys, are successfully used.

Abrasion by grinding / abrasion and pressure

This type of wear occurs when small, abrasive particles enter between the two metal parts,
where they shrink and produce a similar polishing effect.

Such wear is at some parts of the mills, spray nozzles, crushers, mixers, excavator blades,
etc.
The alloys used in this case are manganese austenitic, with martensitic structures and
some alloys containing carbides. Carbide alloys typically contain small and evenly
distributed titanium carbides.

Wear at high temperatures / heat, oxidation, corrosion.

Metals exposed to high temperatures for a long time generally lose their durability, often
resulting in cracking due to thermal fatigue.

For example, molds and tools for forging and shaping hot metals give rise to the thermal
impact caused by cyclical thermal stresses.
When operating in the oxidant atmosphere, a layer of oxides is formed on the surface which
subsequently, due to different thermal expansion, can break and the oxidation cycle
repeats itself.

Martensitic steels with 5-12% Cr are very resistant to thermal fatigue. Chromium alloys
with carbon (chromium carbides) have excellent wear resistance up to 600gC.

To work at even higher temperatures, alloys based on nickel or cobalt are used.

Typically exposed to high temperatures are cylinders of continuous casting machines,

forging molds, extrusion tools, punching, roller clamps, clinker breakers, etc.

Basic material
Loading two groups of base materials by welding:
 Carbon or low alloy steels
 Austenitic manganese steels
Basically, a magnet can be used to distinguish between these two groups of materials.

Carbon and low-alloy steels are strongly magnetized. Manganese austenitic types are not
magnetic, but after ecruising these steels become magnetic.

The recommendations for welding these two groups are completely different.

Carbon and low alloy steels require depending on carbon content and alloying elements,
taking various measures such as preheating, heat treatment after welding, slow cooling, etc.

On the other hand, manganese austenitic steels must be welded without preheating or heat
treatment after welding. The temperature should be kept as low as possible (<200 ° C) as
these materials become fragile by overheating.

The most common welding processes for welding are:

WELDING WITH COATED ELECTRODES (see examples below):

Also known as manual arc welding (MMA)
 covers the largest range of weldable metals
 it's cheap
 is a versatile working method, usable in the open air and in different positions.

TUBULAR WIRE OR ROUND WIRE WELDING (see examples below):

 the range of alloys available, almost identical to the coated electrodes
 high deposition efficiency
 it can also be used outside the workshop (there are many types of self-protective
tubular wires)
 Protective gas is not required for self-contained types

Surface machining requirements.

The requirements for surface machinability must be set high in the choice of the additive
material, since durable loading alloys range from easily machinable to non-machinable. In
addition, many of the high-alloy materials crack along the welding cord, forming fine cracks
to relax and remove the stresses that act on the base material (as info, these cracks do not
affect the application itself in any way, grade hardness, etc.)

Therefore, before choosing the addition alloy, you have to answer the following questions:
Is welding required after welding or is she enough?
Is it possible to have small cracks after welding?
As an approximate rule it can be considered that welding metal with a hardness <40HRC
can be processed. Materials with hardness> 40HRC can only be processed by rectification.
Superficial cracking often does not disturb the operation of the hard loading and does not
produce the exfoliation of the deposited layer. However, if the piece is applied to impact or
bending, it is useful to use a ductile buffer that prevents crack propagation in the base
material.
The risk of cracking is lower when a lower welding current is used and the welding speed is
higher.

Types of materials for welding loading

The materials for welding loading can be divided into groups, depending on their
characteristic properties and wear resistance.
These groups are depending on the composition:
Based on iron:
 martensitic alloys
 austenitic alloys
 alloys with high carb content
Non-ferrous alloys:
 alloys based on cobalt
 nickel alloys