Surfacing

Definition:
It refers to the deposition of a filler metal on a base metal (substrate) to impart some
desired property to the surface that is not intrinsic to the underlying base metal.
There are several types of surfacing:
Hardfacing
Buildup

Weld cladding

Buttering

1. Hard facing or surfacing is a form of surfacing that is applied for the purpose
of reducing
Wear or loss of materials by
Abrasion
Impact
Erosion
Galling
Cavitation.
Hardfacing can be used to extend the usage of life of the
component.

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2. Buildup:
Refers to the addition of weld metal to a base metal surface for the restoration of
the component to the required dimensions.
Buildup alloys are generally not designed to resist wear, but to return the worn part
back to, or near, its original dimensions or to provide adequate support for subsequent
layers of true hard facing materials
3. Weld cladding:
It is a relatively thick layer of filler metal applied to a carbon or low-alloy steel base
metal for the purpose of providing a corrosion-resistant surface.
Weld cladding is normally carried out by
arc welding- SMAW, GTWA, SAW, FCAW
solid-state welding processes (roll cladding or explosion cladding)
vacuum brazing
4. Buttering also involves the addition of one or more layers of weld metal to the
face of the joint or surface to be welded.
It differs from buildup in that the primary purpose of buttering is to satisfy some
metallurgical consideration. It is used primarily for the joining of dissimilar
metals.

Hardfacing:
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Selection of hardfacing
It is necessary to understand the wear that caused the metal deterioration
Classifications of wear
1. Impact Wear
Striking of one object against the another
Battering and pounding types of wear that breaks split or
deforms metal surfaces.
2. Abrasion
The wearing away of the surface by rubbing, grinding or
friction
It happens when hard and soft material rubbing together
It is caused by scouring action of sand, gravel or gritty
material on machining
3. Erosion
The wearing away of the material by abrasion of a liquid
This is also caused by steam or slurry that carry abrasive
materials
Pumps parts
4. Compression
Deformation type of wear caused by heavy static load or
by slowly increasing pressure on metal surface
Compressions wear causes metal to move or lose its
dimensional accuracy
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5. Cavitations
This wear results from turbulent flow of liquids, which
carry suspended abrasive particles
6. Metal-metal wear
This wear is a seizing or galling type of wear that ribs and
tears out portion of metal surfaces
It is caused by metal parts together because of lack of
lubrication
Frictional heat helps to create this problem.
7. Corrosion Wear

Deterioration of metal surfaces by the effects of the

atmosphere, acid, gases.
This type of wear creates pits and damage metal parts

8. Oxidation
This type of wear indicated by the flaking off or
crumbling of metal surfaces
This takes place when unprotected metal is exposed to a
combination of air, heat and moisture.
Rust
9. Thermal shock
It is problem indicated by cracking or splintering,
which is caused by repeated heating and cooling.
Spalling

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Effect of alloying elements of hardfacing materials

Carbon (C)
Combines with other elements to form very hard and wear-resistant carbides.
Carbon is contained in almost all hardfacing alloys.
Chromium (Cr)
Hardness, toughness, wear and corrosion resistance.
With carbon, forms chromium carbides ( M3C, M23C6 , M6C and MC)

Manganese (Mn)
Increases the ability to harden and adds toughness to the deposit.
Molybdenum (Mo)
Increases the strength and hardness.

Improves wear resistance and modifies carbide geometry.

Nickel (Ni)
When combined with chromium up to three percent provides toughness

above seven percent, provides corrosion resistance

Forms stable austenite.

Phosphorus (P)
an impurity
serves no useful purpose in hardfacing deposits
Tungsten (W)
Provides hardness,
Outstanding wear resistance ( M6C, MC)
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 Resistance to softening during tempering.

Vanadium (V)
Improves wear resistance ( MC)
Strength (Grain refiner)
Resistance to softening during tempering ( stable carbides)
Sulphur (S)
Improves machinability of deposits
adds to deposit soundness and tensile strength
Iron (Fe) It is the basic element that appears in almost all hardfacing products
It is referred to as steel when it is combined with small amounts of carbon
Hardfacing Materials:
No standardized method of classifying and specifying the different surfacing weld rods
and electrodes.
Hardfacing materials can be categorized into five groups
Group 1:
Low alloy steels ( Cr as the principle elements)
Sub group 1A 2-6 wt % alloying elements)
These materials used as build-up materials under higher alloy hardfacing
materials.
Group 1B
They have a higher alloy content ( 6-12 wt %)

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Properties of this group

1. Have the greatest impact resistance
2. Have better wear resistance
3. Least expansive of the alloy surfacing materials
4. Have high compressive strength and moderate erosion resistance
Group-2
Contains higher alloyed steels
Group-2A : C r as chief elements with total alloy content of 12 -25 wt%
Many of this alloys contain Mo with high carbon 1.75 wt % - Medium alloy
cast irons
Group 2B : Mo as principal element along with Cr
Properties of 2 A and 2B
Excellent wear resistance
Less shock resistance
More expansive than the group 1 materials
Have high temperature strength
Used for build up purpose
Provide good impact resistance and abrasion resistance at normal
atmosphere
Group 2C: Contains Tungsten (W) and modified high speed tool steels
They have excellent choice at service temperature (up to 600oC)
Good hot abrasion resistance
Exhibit good metal- metal wear resistance at elevated temperatures
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 Group 2D: Austenite manganese steel

Mo or Ni used as stabilizers

They have high shock resistance but limited to wear resistance

unless subjected to work hardening

Total alloy content 12 -25 wt %

Hardness is 170 -230BHN
Group 3
Steel contains higher alloyed composition range of 25 to 50 %
High Cr alloys
Carbon range over 2 to 4 wt %
Properties
Exhibit better impact, erosion and metal to-metal wear resistance
Group 4: Nonferrous alloys
Either Co or Ni based alloys
Total content of alloy is more than 50 %
Group 4D: High Co-based alloys with high Cr

These alloy used for applications subjected to a combination of heat,

corrosion, erosion and oxidation

These alloys are considered most versatile of the hard facing material

They have excellent high temperature strength and good oxidation resistance
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 Group: 5 Tungsten carbide alloys

This deposit consists of WC particles distributed in the metal matrix.
Matrix may be iron, carbon steels, Ni-based alloys, Cu-based alloys and Cobased alloys
Carbide particles are in the range of 8 to 10 mesh
Deposits are not machinable and are very difficult to grind
Microstructure
Consist of hard phase precipitates such as borides, carbides, or intermetallics
bound in a softer iron-, nickel, or cobalt-base alloy matrix.
Carbides are the predominant hard phases in iron- and cobalt-base hardfacing
alloys.
Carbon contents of iron- and cobalt-base hardfacing alloys generally range up to
4 wt%.
Combined carbon plus boron contents generally range up to 5 wt%. The specific
carbide and/or boride phases that form are determined by matrix alloying
additions.
The alloys for matrix purpose are the most of cobalt-, nickel-and high-alloy ironbase hardfacing alloys, generally they contain up to 35% Cr, up to 30% Mo, and
up to 13% W, with smaller amounts of silicon and manganese.

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Hardfacing Process Selection

Hardfacing property and quality requirements
Physical characteristics of the workpiece
Metallurgical properties of the base metal
Form and composition of the hardfacing alloy
Welder skill

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Submerged arc cladding

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Electro slag cladding

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Plasma arc welding

Advantages, Disadvantages and Applications of Plasma Arc Spraying
(i) Almost any base material or substrate can be coated with the plasma spray process.
(ii) High bond strength is obtained.
(iii) The coating is stronger and denser.
(iv) Heat distortion problems are minimum.

Disadvantages of Plasma Spraying

(i) There is a high noise level ranging around 100 dB; this may damage the inner ear.
(ii) There is intense ultraviolet and infrared radiations, which may cause sunburn,
making it essential to provide protection to eyes.

Applications of Plasma Spraying

(i)

Plasma spraying is mainly used for producing wear resistant, temperature

resistant, and heat insulating coatings,

(ii)

(ii) Making rocket parts such as nozzles.

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Thermal-spray is a class of processes designed to deposit a layer of finely divided

particles sprayed upon a substrate, with the purpose of building up the worn out
material or of providing different and enhanced properties on a new surface.
The particles of metals, intermetallic, ceramics or metallic oxides are heated to
elevated temperature and projected at high speed by a special gun, in a heated and
semi-molten condition, on the base metal
They form an adherent coating presenting mechanical interlocking and metallurgical
bond, without fusion of the base metal

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