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JOURNAL OF IRON

ScienceDirect

AND STEEL RESEARCH,

INTERNATIONAL. 2011, 18(11): 74-79

A New Type of Submerged-Arc Flux-Cored Wire Used for

Hardfacing Continuous Casting Rolls
YANG Ke,

ZHANG Zhi-xi,

H U Wang-qin,

BAO Ye-feng,

JIANG Yong-feng

(College of Mechanical and Electrical Engineering, Hohai University, Changzhou 213022, Jiangsu, China)

Abstract: It is expected that the welding hardfacing of continuous casting rolls has better welding performance and
higher wear resistance. A new type of submerged-arc hardfacing flux-cored wire has been developed through nitrogen
replacing part of carbon and addition of the nitrogen-fixing elements of niobium and titanium. And microstructure,
degree of hardness and high-temperature wear resistance of its deposited metal samples were also investigated. It is
found that the microstructure is martensite, residual austenite and carbonitride precipitates. As a result, the hardfacing metal with homogeneous distribution of very fine carbonitride particles had high hardness and excellent wear-resisting property during high-temperature wear, which could significantly extend the service life of continuous casting
rolls.
Key words: submerged-arc flux-cored wire; hardfacing; high-temperature wear resistance; continuous casting roll

A lot of mechanical equipments such as the continuous casting rolls service in aggressive working
environment for long times, which can easily cause
damage and greatly shorten their service life. In order t o increase the service lives, weld hardfacing
techniques are employed t o deposited composite wall
section resistant to high temperature, corrosion and
abrasion on the surfacing of this
Various processes such as gas metal arc welding (GMAW ) ,
gas tungsten arc welding ( G T M A ) , plasma arc
welding (PAW) and submerged arc welding process
have been applied to hardfacing the rolls. Among
these advanced deposition techniques, submerged
arc welding ( S A W ) is one of the most promising
processes because of its higher deposition rate and
lower lost and better surface appearance. Hardfacing procedures involve the use of various types of
welding materials with purpose of generating a set of
properties on the roll surface. Flux-cored wire (FCW)
becomes the most rapidly developed new consumable in
developed country recent years. Alloy ingredients in the
flux-cored wire can efficiently enhance the mechanical
properties and wear resistance of the weld depositC4-'].
T h e martensitic stainless steel (Fe-Crl3-C) is

applied extensively for the surface modification of

the continuous casting rolls because of the fine properties of wear and oxidation resistancesC3'. It is
known that a higher surface hardness is an essential
condition for obtaining higher wear resistance in
most kinds of steels. The hardness of the martensitic stainless steel is increased with increase of carbon
content, but the welding crack resistance and corrosion resistance are decreased. Nitrogen is a gap-atom
element like as carbon and can improve many properties of steels through combining with other alloy
elements"'.
These properties include hardness,
creep resistance, wear resistance and corrosion resistance. On the other hand, it has been reported
that nitrogen may not adversely affect weldability
during weldingCg1.In order to further develop welding performance and wear resistance, the carbon
content of martensitic stainless steel is decreased
through nitrogen replacing parts of carbon, which can
have a carbonitride hardened action on the matrixC'O-l'l.
In view of the above, the submerged-arc hardfacing flux-cored wire of nitrogen alloying martensitic stainless steel is developed, and the aim of the
present study is to investigate the microstructure

Foundation Item: Item Sponsored by National Natural Science Foundation of China ( 5 1 101050) ; Fundamental Research Funds for Central
Universities of China (2009B30214) ; Natural Science Foundation of Jiangsu Province of China (BKZ011257)
Biography:YANG Ke(1983-),
Male, Doctor, Lectureship;
E-mail: yangk@hhuc. edu. cn; Received Date: December 21, 2010

Issue 11

A N e w T y p e of Submerged-Arc Flux-Cored Wire Used for Hardfacing Continuous Casting Rolls

and wear-resisting property of the deposited metal.

Based on the results, the new type submerged-arc
hardfacing flux-cored wire would be applied to hardfacing the continuous casting rolls.

Experimental Procedure

The submerged-arc flux-cored wire was made using

the flux-cored wire manufacturing equipment. The wire
was 3. 2 mm in diameter and consisted of alloying elements in iron powder. All of powder constitutes
40%-50% of the total mass of the wire. Two submerged-arc flux-cored wires (W1 and W2) were prepared. Table 1 gives the compositions of two wires.
In order to alloy the hardfacing with nitrogen, CrN and
strong fix-nitrogen element such as Nb and Ti were
added in the flux-cored wire W2. The substrate used
in this work that was a 450 mm X 250 mm X 10 mm
plate of low carbon steel. Welding flux used was agglomerated flux, and the alkalinity was 1.8 to 2. o.
Table 1 Compositions of two wires of Wl and W2
( m a s s percent,
w1
Deoxidizer (Si, Mn)
Nitrogen alloy (CrN)
Carbonitride former (Nb, Ti)
Alloying element (C, Cr, etc.
Iron power

%)

w2

4-6

4-6

5-8

1-3

30-40

30-40

Balance

Balance

The deposition of submerged-arc flux-cored wire

was conducted using the submerged arc welding under direct current reversed polarity without preheat
or post-heat. The welding conditions were as follows:
welding voltage 30 - 35 V , welding current 400 450 A , wire extension 15 - 20 mm and welding speed
18-23 m/h. T o assure the dryness of the agglomerated flux, it was baked in a furnace at 200 'C for 1 h.
The new type submerged-arc hardfacing flux-cored
wire with good welding performance was deposited
onto the substrate. Dilution is the mixing of the
substrate and the welding wire, and is defined as the
change in the chemical composition of a deposited
metal caused by the admixture of the substrate or
previous weld metal in the weld bead. In order to
get the undiluted alloy and ensure the thickness of
surfacing layers metal was above 15 mm, five layers
of welding were deposited on the substrate. The
chemical compositions of two hardfacing metal (S1
and S2) are given in the Table 2. It could be clearly
found that the chemical composition of hardfacing
metals belonged to one of the martensitic stainless
13Cr-steel series and the sample S1 had adequate N.
The wear tests were carried out on a pin-on-disc
wear tester, which is shown schematically in Fig. 1.
Rectangular shaped samples (pins) with dimension
$6 mmX 12 mm were cut from the deposition of hardfacing metal at room temperature, A disc sample with

Table 2 Chemical compositions of hardfacing metal

%)

( m a s s percent,

Hardfacing metal

Si

Mn

Cr

Nb, Ti

Fe

s1

0. 15

0. 4

1. 5

0. 009

0.007

13. 5

1. 2

0. 12

s2

0. 16

0. 4

1. 4

0. 009

0. 007

13. 6

Balance
Balance

Table 3 Chemical compositions of disc

C
~

Si
_

0. 40

Fig. 1

Schematic illustration of pin-on-disc wear tester

dimension $200 m m X 5 mm was cut from the carbon

steel, and the chemical compositions are shown in
Table 3. T h e roll surface temperature during steady
state service conditions can exceed 500 'C , and material selection of hardfacing metal for continuous casting rolls possess high resistance to wear under the
temperature of 600 oCclzl. So the test temperature
was set at 600 'C and the contact stress was kept on
21 MPa, which were corresponding to the service con-

75

0. 25

Cr

Mo

Fe

0.020

0.015

0. 95

0. 20

Balance

Mn
_

0. 65

( m a s s percent,

%)

dition of continuous casting rolls. The sliding speed of

wear test was 50 m/min and the wear time was 45 min.
The sliding speed of the wear test was 50 m/min and
the wear time was 45 min. An electronic weighing
balance with an accuracy of 1 X
g was used to
weigh the sample before and after wear, and the
mass loss was used as a measure of the wear. For
each submerged-arc flux-cored wire, three samples
of hardfacing metal were made into a group. The
wear test was carried out three times and the averages mass loss was taken for evaluation. The micro-

Journal of Iron and Steel Research, International

76

structure of deposited hardfacing metal was observed

by optical microscope and scanning electron microscopy ( S E M ) and after that the samples were polished and etched by aqua regia. In addition, precipitate phases present in the hardfacing metal were determined by an energy dispersive spectroscopy
(EDS). Hardness measurement of the hardfacing
metal before and after wear was carried out using a
Rockwell hardness test ( H R C ) . T h e hardness was
determined by using the average of five measurements taken on the surface of each sample. And the
average hardness value of each group was made by

Vol. 18

calculation.

2
2.1

Results and Discussion

Microstructure

Microstructure features of bead-welding deposited hardfacing metal S1 are given in Fig. 2. The
bonding of the substrate and deposited metal S1 was
fine without a flaw and porosity, as shown in Fig. 2
( a ) . Fig. 2 ( b ) shows the microstructure of hardfacing metal S1. There are two main phases in the
hardfacing metal S1, i. e. lath martensite and the residual austenite, and lots of dotted precipitates are

( b ) Microstructure of hardfacing metal.

Microstructure features of bead-welding deposited hardfacing metal S1

(a) Bonding of substrate and deposited metal;

Fig. 2

distributing on the grain boundary and the martensite bulk.

T h e pattern and chemical composition of precipitated particles are shown in Fig. 3. These particles
are characteristic cubical shape and the size is small

than 3 . 5 pm, as shown in Fig. 3 (a). The EDX analysis

shows the presence of nitrogen, carbon, niobium and
titanium peaks [Fig. 3 (b)]. So it is determined that
these precipitate particles present in the hardfacing
metal S1 are complex carbonitrides of Nb and TiC13'.

Fig. 3

2.00

4.00

6.00

EnergykeV

S.bO

10.00

Microstructure (a> and energy spectrum figure (b) of precipitates in hardfacing metal S1

After high temperature wearing at 600 ' C , a

large number of carbonitride particles precipitated
and distributed homogeneously on the grain boundary and matrix of the hardfacing metal S1, as shown
in Fig. 4.

2.2

High-temperature wear test

The mass loss of hardfacing metal S1 is 0. 045 g

and mass loss of S2 is 0.056 g. It is observed that
mass loss of hardfacing metal S1 is less markedly
than the S2. Therefore, the wear-resisting property

A New Type of Submerged-Arc Flux-Cored Wire Used for Hardfacing Continuous Casting Rolls

Issue 11

2.00

Fig. 4

Fig. 5

10.00

Fig. 5 ( b ) . So addition of nitrogen to the hardfacing

metal can prevent the formation of chromium-rich
phase at grain boundaries. In this manner the intergranular chromium depletion was prevented efficiently, and the hardfacing metal had good stability
and corrosion resistance at high temperat~re"~'.
Moreover, the precipitation reactions of carbonitride
particles can strength the hardfacing metal efficiently. Table 4 gives the variation in hardness of each
hardfacing metal before and after wear.

SEM images of hardfacing metal S1 (a) and S2 (b)

Hardness of two hardfacing metals before and

after high-temperature wear

Hardfacing metal

8.00

Microstructure (a) and energy spectrum figure (b) of precipitates in

hardfacing metal S1 after high-temperature wear

of the hardfacing metal S1 was more excellent than

that of S2.
The scanning electron morphologies of hardfacing metal S1 and S2 after high-temperature wear are
shown in Fig. 5. Lots of carbonitride particles with
fine size presented in the hardfacing metal S1 and
distributed more homogeneously, as shown in Fig. 5
( a ) . While in the hardfacing metal S2 , a few carbide
precipitates of chromium-rich phase with coarse size
on the grain boundaries can be found, as shown in

Table 4

4.00
6.00
EnergykeV

77

Hardness (HRC)
Before wear

After wear

s1

46. 6

35. 5

S2

50. 6

29. 7

From Table 4, it could be clearly found that

there is an unequally variation in the hardness of two
samples. Before wear, the hardness of hardfacing
metal S1 was lower than that of hardfacing metal

S2. After wear, the hardnesses of both hardfacing

metals were evidently decreased, of which the decrease of hardness in the hardfacing metal S2 was
more significant. And then the hardness of hardfacing metal S1 was higher than that of hardfacing meta1 S2. It is an obvious contrast in the hardnesses of
two hardfacing metals, which means the precipitation of hard phases had a significant effect on the
hardness of hardfacing metal. During the process of
high temperature wear, a large number of carbonitride particles can precipitate extensively out of the
matrix and have better high-temperature stability

78

Journal of Iron and Steel Research, International

than carbides. All these carbonitride particles distributed homogeneously on the grain boundary and
matrix, which had better strengthening effect to the
hardfacing metal. So the hardfacing metal S1 can
keep higher hardness than S2 during the high-temperature wear. Meanwhile precipitation of carbonitrides at high temperature prevented the formation
of chromium-rich carbide phase on grain boundaries,
and then could increase the corrosion resistance of
hardfacing metal. Moreover, the toughness of hardfacing metal could be increased markedly when the
hard precipitates were in granular form and distributed evenly in the metal. So the hardfacing metal
with fine carbonitrides evenly distributing on the
grain boundary and matrix had better roughness
than that of with coarse carbide phases only existing on
the grain boundaryc']. In conclusion, the hardfacing

(a) Rolls after depositing;

Fig. 6

Vol. 18

metal with nitrogen strengthening had better resistance to wear due the combination effect of high
hardness and better toughness at high temperature,
which could effectively prevent the removal of matrix. T h u s , the high-temperature wear damage of
the hardfacing metal S1 was decreased, and the mass
loss of the hardfacing metal S1 became slowly.
Based on the results, an example of hardfacing
continuous casting roll using the new type submerged-arc flux-cored wire is shown in Fig. 6. Fig. 6
( a ) shows the new type submerged-arc hardfacing
flux-cored wire had been deposited directly onto the
roll with good welding performance. And Fig. 6 ( b )
shows the deposited surface of rolls had been made
to the working size by machining. So the hardfacing
metal can enable the service life of the rolls to be extended considerably.

( b ) Rolls after machining.

Hardfacing continuous casting rolls using submerged-arc hardfacing flux-cored wire

Conclusions
A new type of submerged-arc hardfacing flux-

cored wire was prepared through nitrogen replacing

parts of carbon and addition of the nitrogen-fixing
elements of niobium and titanium. By deposited it
onto the substrate, the hardfacing metal with better
surface appearance can be got. And the microstructure of the hardfacing metal of it is lath-shaped martensite, the residual austenite and carbonitrides distributing on the grain boundary and the martensite
bulk. More carbonitrides with fine size can homogeneously precipitate out during high temperature
wear and had great precipitation strengthening
effect on the hardfacing metal. T h e hardfacing metal with homogeneous distribution of very fine carbonitride particles had better wear-resisting property
than the same type of hardfacing metal. And the
wire had been used successfully in hardfacing the

continuous casting rolls, thereby could significantly

extend the service life of the rolls.
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A N e w Type of S u b m e r g e d - A r c Flux-Cored Wire U s e d for H a r d f a c i n g C o n t i n u o u s C a s t i n g Rolls

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